Patent Application
20210024276
The present description relates generally to inflatable units, such as storage devices, storage boxes, cold-storage boxes, shipping containers, protective shipping devices, etc.
Containers may be formed of various constructions. However, structural rigidity and heat transfer reduction can require expensive components, increased weight, and large amounts of spaced when unfilled. The inventors herein have recognized these issues and provide various approaches to address them. In one example, a unit, which may be a shipping container, may include It should be understood that the summary above is provided to introduce in simplified form, a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations or embodiments that solve any disadvantages noted above or in any part of this disclosure.
The following description relates to systems and methods for an inflatable unit constructed from a drop-stitch fabric. Throughout the description, the same reference characters are used to identify common elements across multiple images of each inflatable embodiment.
Turning now
Base cloths 112 and 122 may be tethered via drop stitches 104 to provide a double-wall material of a specified thickness when inflated to a desired pressure. A space 102 may be located between base cloths 112 and 122. As one example, each of base cloths 112 and 122 may be constructed from a polyester material. However, it will be appreciated that in other examples, alternative suitable materials may be used. Drop stitches 104 may also be constructed from a polyester material, although the weight of the drop stitch material may differ from the weight of the material of the base cloths.
The drop stitching may extend through at least a portion of base cloth 112, along the space 102 and through at least a portion of base cloth 122. Drop stitches 104 may comprise a dense array of stitches, and these stitches may be in a linear, zigzag, or random pattern with a stitch density within a range of 6-45 stitches per square inch. The space 102 between the base fabrics 112 and 122 may comprise the drop-stitching thread 104 and air. The space between base fabrics 112 and 122 may be adjusted based on a degree of inflation of the walls of the unit. As one example, the drop-stitch 104 may be in the range of 5-7 centimeters when the cooler is at the desired degree of inflation, the desired degree of inflation determined based on one or more of a desired rigidity of the unit shape and the shear modulus of the drop-stitch fabric. In other words, the spacing between base layer 112 and base layer 122 may be in the range of 5-7 centimeters when the unit is at the desired degree of inflation. In this way, a unit constructed from a drop-stitch fabric may be flexible and compressible when in a deflated state, providing improved portability. Further, the unit may form a rigid shape when in an inflated state to provide a reliable sturdiness, tensile strength, and the ability to store both fluids and solid objects within the walls of the unit.
It will be noted that the drop-stitch 104 and the space 102 may be exposed when drop-stitch fabric 100 is constructed. Thus, the exposed edges of the drop-stitch fabric may be sealed before use as an inflatable chamber, as is described in further detail below with reference to
Inner layers 114 and 124 may be colligated in face-sharing contact to respective base cloths 112 and 122 via the use of adhesives, heat fusion, and/or a combination thereof. Similarly, inner layers 114 and 124 may be colligated in face-sharing contact to respective outer layers 116 and 126 via adhesives, heat fusion, and/or a combination thereof. In one example, the inner layer 114 may be colligated to base cloth 112 via heat fusion. At the same time, the inner layer 114 may be colligated to the outer layer 116 via adhesives. Inner layers 114 and 124 may be constructed from a reinforced polyvinyl chloride (PVC) material, or alternatively may be constructed from one of polyurethane (e.g., a thermoplastic polyurethane TPU) or Hypalon. By colligating an inner layer 114 or 124 to a respective base stitching layer 112 or 122 of the drop-stitch fabric, durability of the stitching may be improved.
As described in further detail with reference to
Turning now to
One object of the present invention is to provide an inflatable unit wall constructed from a drop-stitch fabric and comprising a single inflatable chamber. As used herein, the inflatable unit wall refers to an entire perimeter of the unit, and the inflatable unit wall may comprise a plurality of unit wall faces. A drop-stitch fabric may not be immediately suitable for use as a unit wall at least for the reasons of the exposed drop stitching along the edges of the fabric and the rigidity provided by the outer layer of the drop-stitch fabric, as described above with reference to
Turning to
In another example, the first outer layer 202 of the drop-stitch fabric, composing the exterior face of the unit wall, is scored and the second outer layer, composing an interior face of the wall, is not scored. By scoring the drop-stitch fabric along the exterior face of the unit wall and not the interior face of the unit wall, the compliancy of the drop-stitch fabric may be improved while maintaining a level of rigidity within the inside of the unit, where the walls may be subject to greater stress when storing contents.
The drop-stitch fabric is shown with scored edges 208 and an exposed area 206 formed from the separation of scored edges 208. As one example, the scoring of the drop-stitch fabric may comprise creating an incision through only outer layer 202. In such an example, exposed area 206 may comprise the inner layer of the drop-stitch fabric (i.e., inner layers 114, 124 at
Drop-stitching 204 and exposed area 206 may be sealed by a plurality of sealing fabrics to form a sealed inflatable chamber. As one example, each sealing fabric may be a PVC material. The plurality of sealing fabrics may seal each exposed drop stitching area and each surface that may have been exposed as a result of the scoring process described above. Along any desired bends in the drop-stitch fabric, an additional piece of sealing fabric may be colligated to exposed faces adjacent to the scored edge, thereby providing further strength to the air seal. Each sealing fabric may be affixed to the first outer layer 202 and second outer layer 201 (e.g. an inner and an outer wall of the inflatable unit) via adhesives, heat fusion, and/or a combination thereof. In the example of affixing the sealing fabrics to the first and second outer fabric layers via an adhesive, the adhesive may be applied only to those surfaces that will be in face-sharing contact. Dashed lines in
For instance, edge seals 212 may be affixed to first outer fabric layer 202 and second outer layer 201 via an adhesive, and may span from the second outer layer 201 of the interior surface of the wall to the first outer layer 202 forming the exterior surface of the wall along a direction substantially parallel to the drop-stitching (such as, along an axis normal to the surface of the unit walls). Edge seals 212 may be positioned along the top edge 205 and bottom edge 207 of the unit wall, terminating near any bend in the drop-stitch fabric. As shown in
As indicated by the cut-out edges of each edge seal 212, edge seals 212 may extend along the unit wall perimeter from a first bend in the unit wall to a second bend in the unit wall, the second bend separated from the first bend by a single substantially straight unit wall perimeter section. In another example, a unit wall 200 may comprise a first edge seal 212 extending along the entire perimeter of the top edge 205 of the unit wall, and a second edge seal 212 extending along the entire perimeter of the bottom edge 207 of the unit wall. Edge seals 212 may be provided to the drop stitch fabric of any inflatable chamber of a unit embodiment, and not only to inflatable chambers including scored edges 208 as shown at
Outer scoring seal 214 may span each exposed area 206 of the unit wall. Outer seal 214 may be affixed to first outer layer 202, spanning the unit wall perimeter for at least a distance beyond each scored edge 208 of a single incision. Outer scoring seal 214 may also span the entire vertical extent of the unit wall, e.g. from top edge 205 to bottom edge 207, along the scored edge 208. An outer scoring seal 214 may be provided for each scored edge of the unit wall 200.
Corner seals 218 may be affixed to each of the top edge 205 and bottom edge 207 of the unit wall at each bend (e.g. bend 209) along the perimeter of the unit wall. In some unit embodiments, corner seals 218 may additionally be provided at an interface between two inflatable chambers, at the top and bottom edges of the interface, and spanning from the first inflatable chamber to the second inflatable chamber. As shown at
Corner seals 218 may be provided along each of the top edge 205 and bottom edge 207 of the unit walls. Along each of the top edge 205 and the bottom edge 207, corner seals 218 may extend at least from an end of a first edge seal 212 to an adjacent end of a second edge seal 212, as indicated by dashed lines at
Turning now to
Unit wall 210, accordingly, includes four scored edges 208 per bend in the wall: two on the concave side of the bend 209 in the unit wall (as shown in exploded view 210 of
Inner scoring seal 216 may span exposed area 256 along the concave surface of second outer layer 201 of unit wall. Inner scoring seal 216 may be affixed to the second outer layers 201, spanning the unit wall perimeter for at least the distance between each scored edge 208 of a single incision. To elaborate, inner scoring seal may substantially cover exposed area 256 of the concave side of bend 209 as well as extend beyond scored edges 208 on each side of exposed area 256. Inner scoring seal 216 may also span the entire vertical extent of the unit wall e.g. from top edge 205 to bottom edge 207 of unit wall. Outer scoring seal 214 may be provided for each scored edge of the unit wall 200 on the convex surface of bend 209 as described above with reference to
Corner seals 218 may be provided along the top and bottom edges of the unit wall 210, as described earlier for
Thus, exploded view 200 of a unit wall may include a plurality of sealing pieces such as edge seals 212, corner seals 218, and outer scoring seals 214. Further, exploded view 210 of a unit wall formed using the second method of scoring may include an additional sealing piece for an inside concave surface of each bend in the unit, e.g. inner scoring seals 216. Specifically, exploded view 210 of the unit wall includes a plurality of sealing pieces comprising edge seals 212, corner seals 218, outer scoring seals 214, and inner scoring seals 216.
A first unit embodiment disclosed herein may include a lower section and an upper section, each section optionally constructed from the drop-stitch fabric described with reference to
The bottom inflatable chamber may be one of a number of shapes, including but not limited to a rectangle or an oval. As one example, the shape of the bottom chamber may be created by cutting a sheet of drop stitch fabric to a desired shape, then sealing the edges of the drop-stitch fabric as described above with reference to
In some examples, the side inflatable chamber may be shaped as a ring matching the shape of the bottom inflatable chamber. Bends in the wall formed by the side inflatable chamber may be achieved via one of the two scoring methods described above with reference to
The upper and lower sections of a first inflatable unit embodiment may each include an exterior fabric designed to accommodate various components of the unit while protecting the drop-stitch fabric from excessive wear. For example, the exterior fabric may be PVC and may be affixed to the unit body via adhesives, heat sealing, and/or combinations thereof. However, in other examples, at least a portion of the outer surfaces of the unit may comprise the outer layer of the drop-stitch fabric (as described above with reference to FIGS. 1A-B). In some examples, one or more of the upper and lower sections may include an insulating layer of fabric extending along the interior surfaces which define the internal storage compartment of the unit. As one example, the insulating layer may be constructed from one of Mylar, Melinex, etc.
The unit body, also termed the lower section, may comprise a first and second inflatable chamber. As an example, the first inflatable chamber may be the bottom inflatable chamber as described above, and the second inflatable chamber may be the side inflatable chamber as described above. The first and second inflatable chambers may be integrated to form a contiguous unit body. As one example, the bottom inflatable chamber may be positioned in face-sharing contact with the side inflatable chamber along the entire perimeter of the unit walls, and may also be flush with a bottom portion of an inner surface of each unit wall face. In this way, the inner surfaces of the unit wall (or the side inflatable chamber) and the top surface of the bottom inflatable chamber may together form a storage compartment or storage compartment for storing contents.
The upper section may comprise a single inflatable chamber of a similar shape to the bottom inflatable chamber. Adhesives, heat sealing, interfacial sheets of fabric, and/or a combination thereof may be used to securely integrate the bottom inflatable chamber to the side inflatable chamber forming a single lower section comprising a first and second inflatable chamber. Said integration may be implemented on each of the exterior and interior surfaces of the unit body. In this way, by securely integrating the bottom inflatable to the side inflatable chamber, stability and rigidity of the lower section may be increased when each inflatable chamber is inflated. Rigidity and stability may be desired in a unit for accommodating sitting and/or standing on the unit.
The lower section may be configured to store liquids and solid objects when the bottom chamber and the side chamber are inflated to form a storage compartment within the lower section. In such a configuration, an open region may be formed vertically above the bottom inflated chamber and within the perimeter of the inflated side chamber wall. This open region may act as the storage compartment provided by the lower section. The upper section may provide a cover for the open region of the storage compartment. Further, sealing mechanisms may be integrated into each of the upper and lower sections, as described in further detail below, to enable covering of the open region (or storage compartment). Herein, the upper section may be positioned atop the lower section to cover the storage compartment, and the sealing mechanisms may be actuated to seal the storage compartment. Thus, the upper section can also be referred to as the lid of the inflatable unit. Further, the storage compartment may herein be referred to as an internal storage compartment, as it may comprise a space internal to the unit structure when the compartment is covered.
As used herein, the terms “convex surface”, “exterior surface”, and “outer surface” are used to refer to examples of the surfaces of the unit that are exposed to the surroundings and atmosphere when the inflated unit is shut. Further, the terms “concave surface”, “interior surface”, and “inner surface” are used to refer to examples of the surfaces of the unit that are concealed when the lid of the inflated unit is shut and closed. For example, with reference to the double-wall drop-stitch construction of the unit, when the unit is configured to store liquids, the outer surfaces of the unit include an exterior surface of the bottom of the unit (e.g., an exterior bottom surface of the bottom chamber), a first outer layer of the side inflatable chamber wall (e.g., outer layer 202 at
It will be appreciated that when the inflated unit is shut after inflating, the lid of the unit (also termed, upper section) rests atop the unit body (also termed, lower section) closing the storage compartment formed within the unit body when inflated. As such, the storage compartment in the unit body may be isolated from the surroundings (including air) when the lid of the unit is closed and the unit is shut.
In some examples of the first unit embodiment, the lid may be coupled via one or more hinges to the unit body along a longer edge of the unit body, so that the lid may rotate or swivel about a stationary horizontal axis extending parallel to the longer edge of the side inflatable chamber. For example a sheet of PVC may couple the rear inner wall of the unit body to the rear outer edge of the bottom surface of the lid, and the lid may pivot about this connecting sheet of PVC. One or more hinges may be configured to connect the lid and unit body along adjacent longer edges of each component. With such examples, the vertical face of the unit which includes the hinge is herein referred to as the rear side of the unit and the vertical face opposite the rear is referred to as the front side of the unit, in reference to the fact that the unit is typically opened from the end opposite the hinged end of the unit.
Turning now to
Accordingly, unit wall 300 may include four scored edges 208 per bend in the unit wall: two on the concave side of the bend 209 in the unit wall, resultant from an incision along the vertical extent of the inner surface (e.g. first inner layer 201) of the unit wall, and two on the convex side of the bend 209 in the unit wall, resultant from an incision along the vertical extent of the outer surface (first outer layer 202) of the unit wall. Similar to unit wall 200, the scoring of unit wall 300 may include creating incisions through one or more of the outer layers (such as 116 and 126 of
Inner scoring seal 302 may span exposed area 220 along the concave surface of first inner layer 201 of the unit wall. Inner scoring seal 302 may be affixed to the first inner layers 201, spanning the unit wall perimeter for at least the distance between each scored edge 208 of a single incision. To elaborate, inner scoring seal may substantially cover exposed area 220 of the concave side of bend 209 as well as extend beyond scored edges 208 on each side of exposed area 220. Inner scoring seal 302 may also span the entire vertical extent of the unit wall e.g. from top edge 205, to bottom edge 207 of a unit wall. Outer scoring seals 214 may be provided for each scored edge of the unit wall 300 as described above with reference to
Corner seals 218 may be provided along the top and bottom edges of the unit wall 300 as described earlier with reference to
Thus, exploded views 200, 210, 300, and 310 of a unit wall may include a plurality of sealing pieces such as edge seals 212, corner seals 218, and outer scoring seals 214. Further exploded views 300 and 310 of a unit wall formed via a third and fourth method of scoring may include an additional sealing piece in order to seal an interior concave surface of each bend in the unit body. Specifically, exploded views 300 and 310 of the unit wall may include a plurality of sealing pieces comprising edge seals 212, corner seals 218, outer scoring seals 214, and inner scoring seals 302.
Similarly to
Inner scoring seal 302 of unit wall 310 may span the interior surface of the unit wall and may be in direct contact with a first inner layer 201 of the unit body and may extend across the exposed area 220, reaching the outer scoring seal 214 such that the inner scoring seal 302 and the outer scoring seal 214 may be in direct contact with one another. Edge seals 212 may extend from a bottom edge 207 of the unit body up to the first outer layer of a portion of the drop-stitch fabric 204 that is placed perpendicular relative to the bottom edge 207 of unit body 310. A method of sealing scored edges that may not be paired to other sections of drop-stitch fabric is also provided in
Edge seals 212 may be placed over exposed edges of the drop-stitch fabric such that the seals may lie in direct contact with the bottom edge 207 of the inflatable chamber and may extend upward, relative to the bottom edge, to be in direct contact with the first inner layer 201 of the unit body. It will be appreciated that when sealing an exposed side of the drop-stitch fabric, an edge seal 212 may be placed under inner scoring seals 302 and outer scoring seals 214 such that the scoring seals 302 and 214 sandwich the edge seal 212, effectively sealing the exposed edges and exposed area 220. It will be understood that the embodiment provided herein may also employ corner seals 218 similarly to
As provided in
For example, when fully inflated, the unit body, as defined by the drop stitch fabric walls, may be substantially expanded by the force of introduced air such that the drop stitches 104 within the space 102 of the drop stitch fabric 100 are fully extended. In this way, a first surface 110 and a second surface may be substantially supported by the drop stitches 104 and air within the space 102 of the fabric 100.
As shown in
In at least one embodiment provided herein, the drop stitch fabric 100 may be configured to form the outer perimeter of the unit body wherein the perimeter of the unit as defined by the side walls that are substantially perpendicular to a ground surface.
In such examples, the drop stitch fabric may be configured to include bends. In some examples, the bends of a unit wall may comprise a single drop stitch fabric portion that may be scored along an interior edge of the fabric such that the exterior edge of the fabric may provide an exterior surface of the unit body. Once the interior edge(s) has/have been scored, inner scoring seals 302 may be applied to the scored area of the drop stitch fabric as shown in
In a further exemplary embodiment, the inflatable chamber of the drop stitch unit may comprise at least two portions of drop stitch fabric coupled together via a method of scoring and sealing as described above with reference to
Specifically, in such an embodiment, a portion of drop stitch fabric may be bent in 4 places such that the bends form a substantially square or rectangular shape when viewed from the top down. Once the drop stitch portion has been bent into the desired configuration, the fabric may be sliced along the angle of the bend. In at least one embodiment, the slicing or scoring of the bend angles may traverse only a portion of the drop stitch fabric. In this way, a singular and unitary unit body profile may be achieved.
It will be appreciated that at bend 209 locations, the scoring may substantially traverse at least a portion of the drop stitching 104 of the drop stitch fabric 204. In such an embodiment, the drop stitches 104 may not be fully extended so as to fully support a first surface 110 and a second surface 120 in a parallel arrangement. Further, an area of drop stitching located at the bend 209 location(s) may be cut such that the stitching may be limber and may not fully extend in a substantially linear manner.
In some embodiments, the bends of the unit wall may comprise an interface at which the interior sections of the drop stitch fabric may be in direct face-sharing contact with each other. For example, in some embodiments, when the unit is inflated, the bends may comprise an area at the bend angle edge in which the drop stitching may not be fully extended and may be compressed between a first surface and a second surface of the drop stitch fabric. In this way, air may still fill the entirety of the inflatable chamber while providing a desired shape of the chamber.
In other examples, drop stitch fabric portions may be cut into individual pieces that correspond to each vertical side wall of the unit body and a bottom planar surface of the unit body. Once portions of the unit body are cut and configured to the correct shape, each portion may then be coupled to each corresponding piece via a method of scoring and sealing.
It will be appreciated that when in a deflated state, the drop stitch fabric defining the unit body may comprise a substantially thin profile wherein the drop stitch fabric and the drop stitches within the fabric may not be fully extended and may not be supported by air within the chamber. Specifically, when deflated, in one embodiment, the first surface of the drop stitch fabric may be in direct face-sharing contact with the second surface. In this way, the unit may be more easily stored and/or transported.
Turning now to
As described earlier, wall 402 of unit 400 may comprise an inflated side chamber with a drop-stitch construction. In some examples, an additional layer of fabric may be tightly wrapped around the convex surface of the drop-stitch fabric of the unit walls (e.g., around a first outer layer 202 of the unit wall). In some examples, the same additional layer of fabric may also be wrapped around a bottom surface of the unit, or alternatively a second additional layer of fabric may be wrapped around the bottom of the unit. Though not specifically shown, unit 400 may also include a bottom inflatable chamber integrated with the inflated side chamber in order to form a lower section 420. A plurality of outer scoring seals 214 are shown on an exterior surface of unit 400. In one example of an oval-shaped unit, five outer scoring seals may be distributed across each arched section of the oval walls (one along each arc is shown in
In at least one embodiment, the bends in the unit may surround an area formed by scoring at least one surface of a drop stitch fabric along an interior surface such that the drop stitching 104 may not be fully supported between a first surface 110 and a second surface 120 of the drop stitch fabric. For example, the outer surface of one or more bends 409 may enclose a space occupied by air wherein the drop stitching may not be fully extended between a first surface and second surface of the drop stitch fabric. Additionally, the outer scoring seals may comprise a material that is not drop stitch fabric.
A plurality of interchangeable foot elements 406 may further be located on an exterior bottom surface of the inflatable unit. In some examples, the interchangeable foot elements 406 may protect the exterior bottom surface of the unit 400 from degradation (e.g., degradation via skidding, scratching, etc.) and may improve the friction between unit 400 and a ground surface. Interchangeable foot elements 406 are described in further detail with reference to
Unit 400 may include a coupling sheet 434 coupling the upper section 410 to the lower section 420, as further described below with reference to
A drain valve 444 may further be provided on one or more embodiments of the inflatable unit. The drain valve 444 may be located on a rear exterior face of unit wall 402 and may include a spigot 428. Drain valve 444 may couple the storage compartment of the unit (not shown) on the inside of unit 400 to the outside of the unit 400 when the drain valve is open, and together with spigot 428, the drain valve may provide a way for a controlled draining of liquids from within the unit. By positioning the drain valve and spigot at the rear of the unit, any draining of the unit may be performed with a lower risk of other unit contents falling out of the unit.
Along the shorter edges 413 of unit 400, side webbing straps 435, 436 may be provided to improve the security of the lid closure. A first end of each side webbing strap 435 may be integrated into an outer edge of lid 410 at a center of each shorter edge 413 of unit 400, in a similar manner as the rear webbing straps. A second end of each side webbing strap 435 may be configured to buckle a first end of a corresponding side webbing strap 436 via a webbing clip. A second end of webbing strap 436 may be integrated into an exterior fabric layer of the unit wall 402 in a manner similar to the rear webbing straps. The second end of webbing strap 436 may also be attached along shorter edge 413 of unit 400. The tension between side webbing straps 435, 436, may be adjusted to provide a desired force between lid 410 and unit body 420. Furthermore, side handles 438 may be provided on each shorter edge 413 of the unit wall, vertically below side webbing straps 436, with the side handles secured at each end via each of stitching and circular patches on the outer fabric layer of the unit wall. Side handles 438 may comprise a nylon webbing strap and may further include a neoprene collar. In some examples, the nylon webbing straps of side handles 438 may be tubular and may include a foam rubber core.
In some example unit embodiments, a foam surface 416 may extend across a top exterior surface of lid 410. The foam surface may be secured to the lid 410 via an adhesive. In one example, foam surface 416 may be constructed from ethylene-vinyl acetate (EVA) or EVA derived materials or a similar material. The foam surface 416 may provide a flat surface with improved friction as compared to the drop-stitch fabric of lid 410. Additionally, the use of foam allows for the top surface of the unit to provide an amount of friction even during wet conditions, which may serve to improve the utility of the unit as a working surface across a wide range of conditions. The lid 410 may also include a seal 414 providing an amount of separation between the upper section 410 and lower section 420 of unit 400 when the unit lid 410 is closed. Seal 414 may be manufactured from a foam rubber material such as ethylene-vinyl acetate (EVA), EVA derived materials, or other suitable materials and is discussed further below with reference to
Turning now to
Interior surfaces of each of the upper section 410 and the lower section 420 may be lined with an insulating material 446 in order to improve insulation of the storage compartment 440. As an example, the insulating material may be Mylar. As another example, the insulating material may be a thermal foil layer with a PVC backing. An additional example of an insulating material may comprise an aluminum foil bubble material disposed between PVC layers on long edges of the unit. Still, a further example insulating material may comprise a fabric including a reflective metalized polyester film coupled in a face-adjacent manner to a non-woven substrate via a plurality of hollow polyester fibers needle punched through each of the polyester film and the non-woven substrate. In this further example, the insulating material may be installed such that the reflective metalized polyester film may be exposed to the storage compartment, and the non-woven substrate may be colligated to the interior surfaces of the inflatable unit. In this way, the reflective metalized polyester film may reflect radiant energy toward the source of radiation, thereby insulating the storage compartment from the external ambient atmosphere.
In at least one embodiment, the underside surface 460 of the upper section may not comprise a drop stitch fabric construction. Additionally, inner webbing straps 442 may be constructed from a material other than drop stitch fabric.
Inner webbing straps 442 may be located within storage compartment 440 and may span a width (e.g. a shorter horizontal axis of the unit). For example, inner webbing straps 442 may extend from a rear end 492 of the storage compartment to a front end 494 of the storage compartment 440. In this way, the inner webbing straps, when buckled, may restrain the mobility of any contents within the storage compartment. In an alternate example, inner webbing straps 442 may span the longer horizontal axis of the storage compartment 440. For example, inner webbing straps 442 may extend from a first side 496 to a second side 498 of storage compartment 440 along an axis that is perpendicular to the width (e.g. from rear 492 to front 494) of storage compartment 440. Inner webbing straps 442 may include webbing clips and the tension within the straps may be adjusted to desired amounts. For example, the tension in the inner webbing straps may be based on an amount of contents stored within the storage compartment of the unit. Valve 444 is shown in
Front webbing straps 433 are shown mounted to unit wall 402 at a position above a front handle 430 in a lower section 420 of unit 400. A corresponding set of front webbing straps 435 are shown attached to lid 410 towards a front end of the top surface of lid 410. Front webbing straps 433 and 435 may be configured to buckle together along a front face 482 of the unit via webbing clips to provide a more secure closure. The tension within the webbing straps may be adjusted to enhance a sealing of storage compartment 440.
Coupling sheet 434 is shown attached towards the rear of the unit along the inner surface of unit body rim 424 and along a base 484 of lid 410. When coupling sheet 434 is taut, it may constrain the angular motion of lid 410 about the horizontal axis extending along the rear longer edge of the unit. In this way, coupling sheet 434 may provide a non-releasable coupling mechanism between the lid and the unit body. It will be appreciated, however, that the first unit embodiment 400 may not include a coupling sheet.
It will be appreciated that unit body rim 424 may comprise a plurality of edge seals and corner seals spanning an otherwise-exposed drop stitching of the unit wall, as described above with reference to
Inflation valve 426 is shown on a front surface of wall 402 of unit body 420. When open, inflation valve 426 couples the side inflatable chamber of the unit to the atmosphere and allows for the inflation of the unit wall. Specifically, space 102 within the drop-stitch fabric 100 forming wall 402 of unit 400 may be filled with air. Because the drop-stitch fabric of wall 402 comprises a single inflatable chamber, only a single valve is needed to inflate the unit wall. Inflation valve 426 may be configured to be inflated by a hand pump, for example a hand pump capable of pumping first and second volumes of air. By locating the inflation valve on the outside of the unit, the ease and speed of inflating and deflating the unit is improved. By locating inflation valve 426 on the unit wall opposite the draining valve 444, the rigidity of the unit walls is increased. It will be appreciated that inflation valve 426 may be located at a unit wall face other than the front face without departing from the scope of this disclosure. For example, inflation valve 426 may be located on a side face of the unit wall.
Continuing with
By constructing the seal 414 from a soft foam material, seal 414 with lip 415 may provide a secure, water-tight seal between storage compartment 440 and the surrounding. By positioning the seal on the interior surface of the lid 410 instead of on the unit body 420, degradation of the foam material may be reduced when loading and unloading contents of the inflatable unit. Additionally, seal 414 may reduce wear on an underside surface of lid 410 by protecting the drop-stitch fabric from contact with lower rim 424 when opening and closing the lid. The underside surface may be an interior surface of the lid exposed to the storage compartment 440.
Inflation valve 419 is depicted in
Alternate examples of the first unit embodiment may also include one or more sealing mechanisms comprising magnetic components embedded into each of the upper and lower sections of the unit.
Unit 400 may include unit lid 410 shown herein with several example features. It will be noted that some example units 400 may not include an insulating fabric on the interior underside surface of lid 410. Seal 414 is shown lining the entire perimeter of the interior underside surface of lid 410, and may include lip 415 along the inner perimeter of the seal. Seal 414, in one example, may be made from a material such as EVA. Alternative materials may also be used for seal 414 without departing from the scope of this disclosure. Lip 415 may be configured to align flush with the inner perimeter of the unit body rim 424 of lower section 420. In this way, seal 414 may rest directly on lower rim 424 when the lid 410 of inflatable unit 400 is closed to isolate storage compartment 440 from the surrounding atmosphere. Additionally, lip 415 may provide improved insulation to the storage compartment of the unit body when the inflatable unit lid is shut and closed.
Upper magnetic components 438 are shown embedded within seal 414 of upper section 410. Specifically, upper magnetic components 438 may be located outside the perimeter of lip 415. Each upper magnetic component 438 may be embedded within the seal along shorter sides 655 (e.g. widths) of the seal perimeter such that a length of the magnetic component extends along the front-rear axis of the unit. In alternative examples, upper magnetic components may be included along longer sides of the seal perimeter (e.g. lengths) extending from the front to rear of seal 414 (and unit 400), such that the upper magnetic components may extend along a left-right axis of the unit. As a non-limiting example, upper magnetic components 438 may be rubber magnets glued into recesses within seal 414 that are cut to the dimensions of the magnet. As another example, magnetic components may be integrated into the upper section of the unit via adhesive, heat fusion, sewing, and/or a combination thereof.
Lower magnetic components 439 are shown embedded within lower rim 424. In one example, lower magnetic components 439 may be glued to the drop-stitch fabric of the unit body, and an outer fabric layer (e.g., PVC) may be fit tightly over the drop-stitch fabric to secure the magnetic components 438, 439 in place. As another example, magnetic components may be integrated into the upper section of the unit via adhesive, heat fusion, sewing, and/or a combination thereof. Each lower magnetic component 439 is embedded within the lower rim on the shorter sides 657 of the rectangular perimeter of the lower section 420. The length of the lower magnetic components 439 may extend in a direction substantially parallel to a front-rear axis of the unit. Lower magnetic components 439 may be configured to couple with upper magnetic components 438 embedded within the seal 414 on unit lid 410 when the unit lid is closed. By using magnetic components for sealing the lid to the unit body a more secure closure may be provided to the storage compartment even if the unit is in motion or at an attitude.
Upper magnetic components 438 are configured to couple with lower magnetic components 439 embedded within unit body rim 424 when the unit is shut, and may thereby provide a strong seal to the storage compartment. By incorporating a magnetic seal into the inflatable unit, the strength of the seal is improved relative to that of a traditional webbing clip seal while still maintaining the light weight and compact packing advantages of an inflatable unit constructed from a drop-stitch fabric. A further advantage of a magnetic seal is that the sealing is automatic upon closing the unit, as compared to additional buckling and fastening required in the example of traditional webbing clips. Thus, magnetic sealing components may enable an easier and more efficient sealing mechanism.
In some examples, unit 400 may include a sealing mechanism which comprises a plurality of magnetized clips 450. An example unit 400 may include magnetized clips 450 additionally or alternatively to magnetic components 438 and 439. Magnetized clips 450 may comprise a webbing strap 452 and a magnetized component 454. Each webbing strap may be sewn to lid 410 and further secured via a heat-sealed PVC patch. In some examples the webbing strap 452 may be hollow and may securely house the magnetized component 454. As an alternate example, magnetized component 454 may be secured to the exterior of webbing strap 452 via an adhesive. Each magnetized component 454 may be configured to magnetically couple to a corresponding magnetized component 456 when the unit lid is resting atop the unit body. Magnetized components 456 may be integrated into the exterior of unit wall 402. As one example, magnetized component 456 may be secured to unit wall 402 via an adhesive, a heat-sealed patch, and/or a combination thereof. As illustrated in
Inflation valve 419 is shown on the interior underside surface of unit lid 410, adjacent to a corner 612 of the inner perimeter of lip 415. When in an open state, inflation valve 419 couples the upper section inflation chamber to the atmosphere and allows for the inflation and deflation of the unit lid. Specifically, inflation valve 419 may fluidically couple space 102 of the drop-stitch fabric 100 that forms the lid 410 when the inflation valve is open. Inflation valve 419 may include a cover to protect the valve components when neither inflation nor deflation of the unit lid is occurring. The cover may protect the valve components from the contents of the storage compartment when the unit is shut and the lid is closed to cover the storage compartment. By locating inflation valve 419 on the underside interior surface of the unit lid, and not on the top, exterior surface of the lid 410, the valve may be protected from possible degradation to elements, for example due to heavy use, exposure to environment, and weather.
Storage compartment 440 of
Turning now to
A plurality of base elements 705 may be integrated into the bottom surface of the unit. Specifically, the plurality of base elements 705 may be coupled to peripheral ring 407 and at least partially to region 427. As one example, the base elements may be integrated onto the outer layer of the drop-stitch fabric forming the peripheral ring 407 and region 427 via an adhesive. Alternative joining methods may also be used without departing from the scope of this disclosure. As shown at
Each base element may include an accessory port (not shown) configured to accept an interchangeable foot element 406. The accessory port may include a coupling mechanism (not shown) for securely coupling each foot element. The interchangeable foot elements 406 may then be securely coupled to the unit via coupling mechanisms of the base elements 405. It will be understood that interchangeability of foot elements 406 refers to the possibility of coupling any one of a variety of foot elements to each of base elements 705. As one example, a different variety of foot element 406 may be coupled to each base element 705. In a different example, no foot elements 406 may be coupled to each base element 705 during the use or storage of the unit. By incorporating foot elements onto the bottom exterior surface of the unit, degradation of the unit (e.g., degradation via skidding, scratching, etc.) and unit weight may be reduced. By providing removable foot elements, compact storage of the deflated unit may be achieved.
A technical advantage of providing interchangeable foot elements is to allow the user to select a foot element based on the desired application of the unit. For example, as shown at
Region 427 of bottom exterior surface 720 of the first unit embodiment 400 may also include a bottom inflation valve 445 coupling the bottom inflatable chamber to the atmosphere when the inflation valve is opened. Inflation valve 445 may be configured to be inflated by a hand pump, for example a hand pump capable of pumping first and second volumes of air. Inflation valve 445 may be at least partially recessed within the bottom exterior surface to reduce degradation of the valve. By coupling the entire bottom of the unit body to a single inflation valve, the complexity of inflating and deflating the unit is reduced. By including inflation valve 445 on the bottom exterior surface 720 of the unit, degradation from unit contents such as water may be reduced. A further advantage of including inflation valve 445 on the exterior of the unit is to allow for easier inflating and deflating of the unit when contents are still within the storage compartment.
Between inflation valve 426 described above with reference to
In an alternate representation, an inflatable unit may comprise a first inflatable drop-stitch chamber defining a bottom wall (or a base), a second inflatable drop-stitch chamber defining a plurality of side walls, and a third inflatable chamber defining a lid. The inflatable chambers may be defined by two opposing surfaces of a drop-stitch fabric. The first and second inflatable drop-stitch chambers of the unit may each be constructed from a single sheet of drop-stitch fabric. Further, the bottom wall and the plurality of side walls of the unit may define a unit body, and the unit body may be releasably attached to the lid via a magnetic seal. The inflatable unit may further comprise a plurality of flexible seals non-releasably integrated into the unit body, said flexible seals spanning the vertical extent of the side walls. The unit may further comprise a plurality of interchangeable plastic elements integrated into a bottom (exterior) surface of the bottom wall. The bottom wall and side walls of the unit may define a unit body, and the unit body is releasably attached to the lid via a plurality of webbing clips.
A second unit embodiment contemplated herein may comprise only a contiguous unit wall. In a first example, the unit wall may comprise a single inflatable chamber constructed form a drop-stitch fabric, and said drop-stitch fabric may be scored and sealed to conform to an envelope shape. It will be appreciated that the drop-stitch fabric of the first example may be scored according to one of the first and second scoring methods described above with reference to
Turning now to
Unit 800 includes a first face 810 and a second face 820. Second face 820 may be substantially parallel to first face 810. When first face 810 and second face 820 are substantially parallel to each other, respective lateral ends 812 and 814 may be referred to herein as “adjacent lateral ends”, and respective lateral ends 816 and 818 may be referred to herein as “opposite lateral ends”. Each lateral end extends from a top end of a unit face to a bottom end of a unit face. Similarly, respective top ends 811 and 813 may be referred to herein as “adjacent top ends”, and respective top ends 815 and 817 may be referred to herein as “opposite top ends”. Each top end extends from a first lateral end of a unit face to a second lateral end of a unit face. First face 810 and second face 820 may be attached to each other via a plurality of elements (e.g., at least elements 822, 823, and 825) to form a storage compartment 840. Thus first face 810 and second face 820 may enclose storage compartment 840.
Second unit embodiment 800 may be configured in one of a first example configuration or a second example configuration. In the first example configuration, the unit body may comprise a single inflatable chamber, and each face 810, 820 may be formed from a common sheet of drop-stitch fabric. A plurality of sealing elements may be provided to form an air-tight inflatable chamber from the common sheet of drop-stitch fabric. The plurality of sealing elements forming the air-tight inflatable chamber may further act as water-tight seals for a storage compartment formed between adjacent surfaces of first face 810 and second face 820. In the second example configuration, the unit body may comprise a first and second inflatable chamber. Specifically, first face 810 may comprise a first inflatable chamber, and second face 820 may comprise a second inflatable chamber. Each inflatable chamber may be coupled via a plurality of sealing elements to provide a water-tight seal for a storage compartment formed between adjacent surfaces of first face 810 and second face 820. It will be understood that the air-tight seals of the second configuration are unique to either the first face 810 or the second face 820, and are not achieved by any sealing elements that couple the two faces.
In the first example configuration of the second unit embodiment, each of first face 810 and second face 820 may be constructed from a common sheet of drop-stitch fabric. Accordingly, unit 800 may comprise a single, common and un-divided inflatable chamber. The drop-stitch fabric may be scored along the bottom edge of the unit according to one of the first and second scoring methods described above with reference to
First face 810 and second face 820 of the drop stitch fabric may be nonreleasably coupled along adjacent lateral ends 812 and 814 via inner seals 823. Further, first face 810 and second face 820 may be nonreleasably coupled along opposite lateral ends 816 and 818 via outer seals 822. As shown, seals 822 and 823 may span the entire vertical extent of the lateral ends of unit 800. Specifically each of seals 822 and 823 may extend from the top of second unit embodiment 800 (e.g. from top edges 824) to the base (or bottom) of second unit embodiment 800. In this way, the single inflatable chamber first configuration of the second unit embodiment includes the spaces between outer seals 822 and inner seals 823. Thus the single inflatable chamber of the first configuration may extend outward from an inner perimeter comprising adjacent surfaces of the respective first and second unit faces 810, 820 and inner seals 823, toward an outer perimeter comprising opposite surfaces of the respective first and second unit faces 810, 820 and outer seals 822. The single inflatable chamber of the first configuration may further extend from a bottom end of the unit to a top end of the unit. It will be understood that at least a portion of the single inflatable chamber may be spanned by drop stitching as indicated by the vertical-line fill of first face 810 and second face 820, however other portions of the single inflatable chamber may not be spanned by drop stitching.
First face 810 and second face 820 may not be coupled along the adjacent top ends 811 and 813 of each face in order to provide access to a storage compartment 840 that is formed from the coupling of the bottom, left, and right edges. First face 810 and second face 820 may further be sealed at each top edge 824 of the drop-stitch fabric via a plurality of top edge seals. It will be understood that the top edge 824 differs from any top end 811, 813, 815, 817 in that the surface normal vector of top edge 824 points vertically upward (that is to say, the top edge surface normal vector is parallel to vertical 898) while the surface normal vectors of the top ends 811, 813, 815, and 817 point either into or out of the plane of the page (that is to say, the top end surface normal vectors are perpendicular to each of vertical 498 and the lateral extent of the unit). The top edge seals may extend along the entire perimeter of the top edge 824, thereby providing an air-tight seal for the drop-stitch fabric. In this way, unit 800 may comprise a single inflatable chamber.
In the first example configuration of the second unit embodiment, inflation valve 826 may be provided on an exterior surface of the unit 800 to inflate (or deflate) the entire unit wall. Inflation valve 826 may be configured to be inflated by a hand pump, for example a hand pump capable of pumping first and second volumes of air. By locating the inflation valve on the exterior surface of the unit, the ease and speed of inflating and deflating the unit is improved. Inflation valve 826 may be similar to the inflation valves described earlier with reference to the first unit embodiment.
In a second example configuration of the second unit embodiment, first face 810 and second face 820 may comprise separate and distinct drop-stitch fabrics. As such, first face 810 and second face 820 may comprise separate and distinct inflatable chambers. Conversely, the first face 810 and second 820 in the first example configuration of the second unit embodiment described earlier may be formed from a single drop-stitch fabric. It will be understood that in the second configuration of the second unit embodiment, the spaces between outer and inner seals 822, 823 are not part of any inflatable chamber.
Returning to the second example configuration of the second unit embodiment, each inflatable chamber may be sealed by a plurality of edge and corner seals as described above with reference to
Referring still to the second example configuration, a horizontal cross section of each inflatable chamber is shown by the vertical-line fill. The first and second unit faces 810, 820 may be coupled along their adjacent lateral ends via inner seal 823, and along the opposite lateral ends via outer seal 822. Specifically, inner seal 823 may be affixed on an interior surface while outer seal 822 may be affixed on an exterior surface. As shown, outer seals 822 and inner seals 823 may span the entire vertical extent of each unit face. To elaborate, each of outer seals 822 and inner seals 823 may extend from the top end of the unit to the base of the unit. It will be appreciated that in the second example configuration of the second unit embodiment, the space between outer seals 822 and inner seals 823 is not an inflatable chamber. However, the space may provide a water-tight seal between storage compartment 840 and the outside of the unit (e.g. surroundings).
Further, the adjacent bottom edges of each unit face may be coupled via an interior bottom seal (not shown) on the interior of storage compartment 840, while the exterior bottom edges of each face may be coupled via exterior bottom seal 825. Exterior bottom seal 825 may span the entire lateral extent of each unit face. As an example, exterior bottom seal 825 may span the first unit face 810 from a left opposite lateral end 816 to a right opposite lateral end 816, and may span the second unit face 820 from a left opposite lateral end 818 to a right opposite lateral end 818. Similarly, the interior bottom seal may extend along the first unit face 810 from a left adjacent lateral end 416 to a right adjacent lateral end 416, and along the second unit face 820 from a left adjacent lateral end 818 to a right adjacent lateral end 818. In this way, a water tight storage compartment 840 may be formed between unit faces 810, 820.
In the second example configuration of the second unit embodiment, a first inflation valve 826 may be provided on the exterior of the first face 810 to inflate the first unit face. Additionally, a second inflation valve (not shown) may be provided at the exterior of the second unit face 820 to inflate the second unit face. Thus the second example configuration of the second unit embodiment may thus include a separate inflation (and deflation) valve for each face. On the other hand, the first example configuration of the second unit embodiment may include a single inflation valve to inflate or deflate the entire unit embodiment.
Each inflation valve on the first face 810 and second face 820 of the second example configuration of the second unit embodiment may be configured to be inflated by a hand pump, for example a hand pump capable of pumping first and second volumes of air. By locating each inflation valve on the outside of the unit, the ease and speed of inflating and deflating the unit is improved. Each inflation valve may be similar to the inflation valves described above with reference to the first unit embodiment.
The interior surfaces of unit 800 may be lined with an insulating material 846 to improve insulation of the storage compartment. Specifically, storage compartment 840 may be lined with the insulating material 846. As an example, the insulating material may be formed of Mylar. As another example, the insulating material may be a thermal foil layer with a PVC backing. In this way, the storage compartment 840 of unit 800 may provide a thermally insulated compartment for storing contents at a desired temperature.
Sealing mechanism 850 may be provided along the adjacent top ends 824 of first face 810 and second face 820. In the depicted example, sealing mechanism 850 is a zipper extending from a first lateral end of the unit to a second lateral end of the unit (e.g., from the left end to the right end as indicated at
Handle 830 may be provided on the first face 810, and a corresponding second handle (not shown) may be provided on the second face 820. Handle 830 may comprise a nylon webbing strap and may further include a neoprene collar. In some examples, the nylon webbing straps of handles 830 may be tubular and may include a foam rubber core. Handle 830 may provide the user with a device for adjusting the exposure of storage compartment 840, and further may provide a holder for transporting unit 800.
Lateral handles 838 may be provided on each lateral end of the unit, vertically below shoulder strap 839, with the lateral handles 838 secured at each lateral end via a combination of stitching and circular patches on the outer fabric layer of the unit wall. As one example, a first end of each lateral handle 838 may be secured to the first face 810 of unit 800, and a second end of each lateral handle 838 may be secured to the second face 820 of unit 800. Lateral handles 838 may comprise a nylon webbing strap and may further include a neoprene collar. In some examples, the nylon webbing straps of handles 838 may be tubular and may include a foam rubber core. Lateral handles 838 may provide the user with a device for adjusting the exposure of storage compartment 840, and further may provide a device for transporting unit 800.
Shoulder strap 839 is shown attached to each lateral end of unit 800. Shoulder strap 839 may include two hooks 855 which releasably couple shoulder strap 839 to two plastic loops 856, and each plastic loop may be secured to a lateral end via webbing that is stitched into the unit wall. It will be appreciated shoulder strap 839 may include a securing mechanism other than the clips and loops described herein. It will be further appreciated that the securing mechanism may be at positions along the unit wall other than the lateral ends. Shoulder strap 839 may provide the user with additional options for transporting unit 800.
Thus, a first method is contemplated herein for constructing an inflatable unit, comprising constructing each of a first and second face of an inflatable unit body from a single sheet of drop-stitch fabric. The method may further include defining a bottom end of the unit body via a scoring of the outer surface of the drop-stitch fabric, and defining first and second lateral ends of the unit via each of a first interior seal, a first exterior seal, a second interior seal, and a second exterior seal. The unit constructed via the first method may comprise a single inflatable chamber. A second method for constructing an inflatable unit is contemplated herein comprises constructing a first face of an inflatable unit body from a first sheet of drop-stitch fabric, and constructing a second face of the inflatable unit body from a second sheet of drop-stitch fabric. The second method may further comprise defining a bottom end of the unit body via each of an interior and exterior bottom seal, and may further comprise defining a first and second. The unit constructed via the second method may comprise two inflatable chambers.
A third embodiment of an inflatable unit may include an inflatable unit body comprising a single inflatable chamber, said chamber constructed from a single piece of drop-stitch fabric. The unit body may include a first inflation valve located on the bottom surface of the unit or alternately located on a front unit wall. The unit body may include handles on the outer surface of each unit wall. The unit body may include a draining valve integrated into the bottom of the rear unit wall to allow for the draining of liquids from the storage compartment defined by the unit body. The bottom of the unit body may include interchangeable plastic foot elements with base elements integrated into the bottom surface of the unit. In some embodiments, the third inflatable unit embodiment may further include an inflatable lid constructed with drop-stitch fabric. The inflatable lid may include one or more of a seal along the perimeter of the bottom surface, an insulating material different than the drop-stitch fabric lining the entire bottom surface, and an inflation valve integrated into the drop-stitch fabric at a corner of the bottom surface. The lid may further include magnetic components along the perimeter of the bottom surface and the magnetic components may be embedded within a seal of the lid. As one example, magnetic components may be integrated along the shorter sides of the bottom surface of the inflatable lid. Magnetic components may be correspondingly integrated into the upper rim of the unit body along shorter sides of the unit body, and may be configured to couple to the magnetic components of the inflatable lid. In some further embodiments, the unit may also include magnetic components along the front and rear sides of the unit lid configured to couple to corresponding magnetic components on the rim of the unit body. In some examples, these magnetic components may be in addition to webbing clips releasably coupling the unit body to the unit lid at the front and rear walls of the unit. The storage compartment may include webbing clips spanning a horizontal axis of the storage compartment to secure the contents of the unit.
A third example unit embodiment provided may be a “bag style” unit in which the unit may resemble a tote bag for instance, and where the unit may be held and/or transported by straps that may be placed onto the exterior surface of the unit. Further, this bag style unit may be constructed of a unique, three-sided drop-stitch inflatable chamber which may define the body of the unit, having a substantially rectangular profile shape when viewed from the front or rear faces. The three sides of the inflatable chamber may include a bottom surface, and the two least substantial side walls with respect to length. The remaining two sides of the unit's rectangular profile may be constructed from flexible high density foam, and the entirety of the unit embodiment may further be disposed within an external layer. In this way, the unit may form a rigid support structure on the walls constructed from the drop-stitch fabric that may allow for the unit to support itself while affording the possibility of “over packing” the storage chamber such that the sides of the unit constructed from high density foam may expand beyond the primarily rectangular profile shape of the example embodiment. The external layer of the inflatable bag style unit may comprise a waterproof fabric such as PVC, HYPLON, or urethane. This external layer may provide additional support when carrying and/or transporting the unit as well as potentially increasing its longevity.
Another example unit embodiment disclosed herein may include an inflatable chamber section, also referred to herein as the unit body and may be constructed at least partially of a drop-stitch fabric described with reference to
In some examples, the inflatable chamber may be shaped as a trapezoid with respect to its vertical cross section. Bends in the walls of the inflatable chamber may be achieved via one of the methods of scoring as described above with reference to
In one example embodiment, the top layer 930 of the unit may be constructed of a material that is not drop stitch fabric. Additionally, upper front and rear 928 faces of the unit may be constructed from a material other than drop stitch fabric. In this way, a single, unitary inflatable chamber construction may be achieved while allowing for some degree of flexibility to the unit's body. Further, as described above, the exterior surfaces of the inflatable unit may be constructed of a material such as PVC such that the exterior layer fully surrounds the unit body as defined by the inflatable chamber. For example, logo area 912 may be located on the exterior layer defining the unit's exterior surface.
The bottom and sides may include an exterior waterproof fabric designated to accommodate various components of the unit while providing a protective layer for the drop-stitch fabric comprising the inflatable chamber positioned underneath. The exterior fabric surrounding the drop-stitch construction may serve as a protectant from excessive wear resultant from active use of the unit. For instance, the exterior fabric may be a waterproof fabric such as PVC and may be affixed to the unit body via adhesives, heat sealing, and/or combinations thereof. However, in other examples, at least a portion of the outer surfaces of the unit may comprise the outer layer of the drop-stitch fabric. In some examples, one or more of the sides of the unit body may include an insulating layer of foam sandwiched between a layer of PVC extending along the exterior surface of the unit wall chamber, defining the internal storage compartment, and the interior surfaces of the exterior fabric layer. That is, the inflatable unit may include a layer of high density foam sandwiched between layers of exterior-facing drop-stitch fabric (comprising the unit's inflatable chamber) and PVC.
In some examples of the present embodiment, the unit body may be comprised of a single, continuous, inflatable chamber that may include a bottom portion of the chamber coupled to the two lesser extents of a substantially rectangular front profile. The two greater extents of a substantially rectangular profile may include an insulating layer of foam. The foam lined sides of the unit may be joined at their outermost longitudinal ends. In this way, when the unit is closed via a zipper or other mechanism atop the unit body, the interior compartment of the unit may be isolated from the surroundings, including air, when the unit is closed.
In one example inflatable unit embodiment, the top exterior section 930 and the top exterior flaps 931 are not comprised of any portion of a drop-stitch fabric. The exterior layer, inclusive of the top layer 930, a front exterior face 940, a rear exterior face 938, corner sections 932, and upper front and rear faces 928 of the unit's exterior are constructed from a fabric other than the drop-stitch fabric described above with reference to
One example embodiment provided in
Components such as the drain plugs 902 however, may fully traverse a foam lined layer 1002 of the unit's exterior layer so as to be fully functional as a drain. The foam lining around the drain plug may help to reduce the potential loss of insulation resulting from the drain plugs being placed into the unit. Further, components such as the air valve 906 used to inflate and deflate the unit body may be affixed to the exterior surface of the unit in a way so as to fully traverse the exterior fabric layer and at least partially traverse the first outer layer of the inflatable chamber that defines the unit body. In other words, the air valve 906 may be affixed to the unit such that the inflatable chamber may only be punctured on the outer layer 201 of the unit body. In this way, air may not leak into the storage cavity, and the structural integrity of the inflated, rigid unit body may be maintained.
Turning now to
It will be understood that the exterior layer of the unit, also referred to as the outer lining and the outer section, as used herein, does not comprise any inflatable drop-stitch components and may be affixed to the exterior faces of a unit body as defined by an inflatable drop-stitch chamber via adhesives, heat fusion, and/or a combination thereof. Further, the exterior layer or at least a portion of the exterior layer may be constructed of a durable and waterproof fabric such as PVC or nylon or a combination thereof.
A loop strap 914 may be affixed to each of the exterior front 940 and exterior rear 938 surfaces of the outer lining of the unit embodiment. Further, the loop strap 914 may extend from the middle third of the top section 930 of the unit's exterior and may form a loop for carrying the unit above the middle of the unit. The loop strap 914, may be secured to the unit exterior layer via a double stitched strap extension 913 that may be affixed to the unit exterior in a way that visually divides the exterior section of the unit into thirds. The middle third section of the exterior layer of the unit may be defined by the strap extension 913 and may feature a padded web handle 908 within the two sides of the strap extension. Further, the strap extension may begin at the top of the double layered bottom 922 of the unit exterior and may extend upward to the top layer 930. When the unit is to be transported, the loop straps of the front 940 and rear 938 exterior faces may be joined together via a padded Velcro handle 924. The loop strap and the exterior surfaces forming the front 940 and rear 938 faces as well as the top layer 930 of the unit embodiment may be constructed at least partially from a material such as nylon or PVC an combinations thereof or other suitable and durable material that may provide added protection. The top section 930 of the unit's exterior may form a fabric surface onto which may be attached a zipper assembly 918. The zipper assembly described may be comprised of two sides of corresponding teeth and zipper pulls 904. The zipper assembly 918 may include two zipper pulls 904 which may include t-shaped handles in order to allow for opening the unit from either end. The zipper pulls 904 affixed to the top section 930 of the unit exterior may be used to open and close the storage space defined by the walls of the inflatable chamber that comprise the unit body. It will be appreciated that the unit body may, in an inflated state, form a rigid body defining at least two sides of the unit and a bottom section of the unit in a single and continuous inflatable chamber that may be comprised at least partially of a drop-stitch fabric described above with reference to
The front exterior surface 940 and rear exterior surface 938 of the example embodiment of inflatable unit may be joined to one another on their topmost faces via the top layer 930 and may be opened and closed via the zipper assembly 918. It will be understood that the material of construction for the top layer 930 and the front and rear exterior surfaces, 940 and 938 respectively, may be common. For example, if the top layer 930 of the unit's exterior surface is constructed at least partially from a material such as PVC, then the same may be true of both the rear 938 and front 940 exterior surfaces of the unit. When opened, the top layer 930 may at least partially expose the storage space defined by the unit body. The exterior surfaces of the unit may include features or components that supplement the usefulness of the unit such as straps and handles. For example, the exterior front 940 and rear 938 surfaces may include a double stitched extension of the looped strap 913 to secure the loop strap 914 to the exterior surface of the unit embodiment. The double stitched extension 913 described may be inclusive of a padded web handle 908 extending from the innermost edges of the strap extension 913 and the padded web handle 908 may be used to carry or transport the unit. Each of the front exterior 940 and the rear exterior 938 sections of the outermost surface of the unit body may be inclusive of drains 902 that may be positioned on opposite diagonal ends of the unit body, and may also include a space for logos 912 on the remaining two opposing diagonal corners of the unit. The drains 902 that may be affixed to the exterior surfaces of the unit body may be positioned in a manner that does not interfere with the unit body (i.e. the inflatable chamber that defines the unit body). In this way, a drain may be positioned above the bottom section of the unit body's inflatable chamber, and within the space defined by the at least two outer walls of the unit's drop-stitch chamber. By including drains on each of the most longitudinal sides of the unit liquids may be drained from the storage space while still maintaining the rigidity of the unit when in an inflated state. The drains 902 may further be positioned in a manner in which they extend from the bottom of the upper front and rear faces 928 of the unit through a foam lined layer 1002 of the exterior surface that may not be at least partially constructed of a drop-stitch inflatable chamber.
Turning to
It will be noted that the corner section 932 may be constructed at least partially from a durable material such as PVC or other suitable material such that the exterior sides 926 and both rear 938 and front 940 sections of the unit embodiment provided may be a common material although other materials may be used in further example embodiments. The upper front and rear faces 928 may be the exterior faces of the unit that may include drains 902 and logos 912 as described above with reference to
When closed and secured via the zipper assembly 918, the storage space defined by the unit body's side profile of the present embodiment may form a substantially trapezoidal shape wherein the bottom edge 922 of the unit body may comprise the longer of the two parallel sides of the trapezoidal profile. In this way, the unit may form a rectangular shape when opened fully and the profile shape may be variable depending on the level of inflation of the unit body and whether or not the unit is in an open or closed state with regard to the zipper assembly 918 being opened or closed. When viewed in a side profile view as shown in
The unit exterior may fully encapsulate the inflatable chamber of the unit body within an outer layer that may be constructed of PVC or another suitable durable material. The unit's exterior may also include other spaces for labels 916 that may contain warnings or brief instructions regarding safe handling of the unit embodiment. The spaces for labels 916 may be placed onto the unit exterior so as to not interfere with operation of the unit and not to block or obstruct any of the features or components affixed to the unit exterior. For example, labels 916 may be placed above the air valve 906 in some example embodiments of the inflatable drop-stitch unit and below the padded web handle 908 with orientations and placements not limited to these. Further, the padded handle 908 of the example unit embodiment may lie equidistant from the top and bottom sections of the foam lined 1002 front 940 and rear 938 faces of the exterior unit surface.
It will be understood that the placement of exterior components that do not traverse the interior and exterior of the unit may vary more widely than the placement of exterior components that do traverse the interior and exterior of the unit due to the possibility of interference with the unit body's inflatable chamber. For this reason, the components that traverse the interior and exterior of the unit such as air valve 906 and drains 902 may be strategically placed such that they may perform their desired function while not restricting various aspects of the unit embodiment design. For example, the air valve 906 may be placed elsewhere along the unit so long as the valve may effectively inflate and deflate the unit body's inflatable chamber and the chamber may stay inflated when the valve is closed. Similarly, the drains 902 of the unit may be placed elsewhere along the foam lined layer 1002 of the front and rear exterior sections 940, 938 such that the drains 902 may not be directly coupled to or contact the inflatable chamber that defines the unit body. In this way, an inflatable drop-stitch unit may be inflated independently of the storage space defined by the unit body being filled or emptied. View 920 shows the loop straps 914 affixed to each of the front 940 and rear 938 exterior faces of the unit. In this view, the coupling of the two loop straps via the padded Velcro handle 924 may be inferred.
Turning now to
The side walls of the unit body (i.e. the lesser extents of the rectangular profile) of this embodiment, may comprise the drop-stitch fabric 204 wherein the first inner layer 201 of the drop-stitch fabric may form the interior of the unit body and wherein a first outer layer 202 is coupled to an exterior fabric such as PVC that encapsulates the unit body and the foam lined sides 1006. The first inner layer 201 may be coupled to the interior bottom section 1004 of the unit body by any one of a method of scoring and sealing as described above with reference to
In embodiments including flexible front and rear edges, the flexible edges may be comprised of a material other than drop stitch fabric. For example, the bottom interior section 1004 of the unit body may be coupled to the side walls 1012 via a method of scoring and sealing as described above. Since the bottom interior surface and the two least longitudinal ends of the unit body may be coupled forming a single inflatable chamber, the unit body may define a substantially u-shaped profile when viewed from the front or rear. The two most longitudinal ends of the unit body however may not be constructed from a drop stitch fabric such that when fully inflated, the unit may still retain a level of flexibility while exhibiting a substantially rigid body.
The exterior features of the unit embodiment may be positioned in a manner either traversing the interior and exterior of the unit such as the drains 902 placed on the front and rear surfaces or may be placed such that they may be affixed solely to the exterior surfaces such as the double stitched extension of the loop strap 913 and the padded handle 908 on the front and rear exterior faces of the unit illustrated with a dashed line.
View 1010 shows how the unit body, defined by the drop-stitch inflatable chamber, may form a substantially u-shaped storage space when in a fully inflated state. The entirety of the unit body as defined by the inflatable chamber may be constructed at least partially from drop-stitch fabric 204 and may include an exposed area along the corners formed at bends within in the chamber construction that may not include drop-stitching. In this way, it may be possible to construct the chamber illustrated by
Similarly to
An additional embodiment of a collapsible inflatable drop-stitch unit provided herein may include an inflatable unit body comprising a single inflatable chamber, constructed from a single piece of drop-stitch fabric similar to the embodiments discussed and described above. This example embodiment may form a slightly less trapezoidal profile shape when viewed on its side profile, relative to the example embodiment shown in
Similar to the earlier provided embodiments, a plurality of logos 912, drains 902, web handles 908, and loop straps 914 may be affixed onto the exterior fabric of the unit. The components such as the loop straps and web handles may be affixed to the exterior surface of the unit such that they do not cross into the storage cavity of the unit and may be in direct contact with only the external layer. Components such as the drains and air valve 906 may however fully traverse one or more layers of the exterior surface of the unit or the unit body defined by the inflatable chamber so as to not interfere with the usability of the unit. Specifically, the drains may fully traverse the external layer of the unit and the foam lining 1002 of the side external layers, while the air valve 906 may fully traverse the exterior fabric layer but may only traverse the first outer layer 202 of the drop-stitch inflatable chamber.
The additional example embodiment views described above and provided in
In embodiments including flexible front and rear edges, the flexible edges may be comprised of a material other than drop stitch fabric. For example, the bottom interior section 1004 of the unit body may be coupled to the side walls 1012 via a method of scoring and sealing as described above. Since the bottom interior surface and the two least longitudinal ends of the unit body may be coupled forming a single inflatable chamber, the unit body may define a substantially u-shaped profile when viewed from the front or rear. The two most longitudinal ends of the unit body however may not be constructed from a drop stitch fabric such that when fully inflated, the unit may still retain a level of flexibility while exhibiting a substantially rigid body.
Yet another example inflatable drop-stitch bag style unit comprising an exterior layer that is not constructed from a drop-stitch fabric as described above with reference to
A drain plug may be affixed to an upper corner of the unit's exterior such that it fully traverses both the unit's external layer and the foam lining 1002 of the side walls not constructed from a drop-stich fabric. In this way, the drain plug 1306 may serve as a way to fill the unit body with water as well as provide overflow protection if the unit were to become overfilled with liquid. The drain plug 1306 may provide additional capabilities to the unit not afforded by those of prior art. For example, filling the unit with water may allow for filling the unit with water in order to use the unit as a portable tank to house live bait. Further, the drain 902 and hose plug 1306 may allow for the water within the unit to be removed and replaced with fresher water to prolong the unit's functionality as a bait tank. Additionally, the hose plug may be used to flush and rinse the storage compartment of the unit when it is to be cleaned. Another exterior feature provided in this example embodiment is a mesh layer which may serve as a pocket 1302 and may be affixed onto the outermost exterior surface of an upper front face 928 of the unit via adhesives, heat fusion, stitching, and/or a combination thereof.
Turning now to
Additionally, labels and logos 912 may be affixed to the exterior layer such that their placement does not affect or hinder the usefulness of other exterior features such as the drain plugs 902 or the loop strap 914. For example, a label 912 may be affixed onto a front surface of the unit's exterior layer below the zipper assembly 918 and above a padded handle 908 such that the logo is clearly visible, and the handle 908 and zipper assembly 918 may still be used to transport or open and close the storage compartment respectively. Further, the embodiment provided in
A drain plug may be affixed to an upper corner of the unit's exterior such that it fully traverses both the unit's external layer and the foam lining 1002 of the side walls not constructed from a drop-stitch fabric. In this way, the drain plug 1306 may serve as a way to fill the unit body with water as well as provide overflow protection if the unit were to become overfilled with liquid. The drain plug 1306 may provide additional capabilities to the unit not afforded by those of prior art. For example, filling the unit with water may allow for filling the unit with water in order to use the unit as a portable tank to house live bait. Further, the drain 902 and hose plug 1306 may allow for the water within the unit to be removed and replaced with fresher water to prolong the unit's functionality as a bait tank. Additionally, the hose plug may be used to flush and rinse the storage compartment of the unit when it is to be cleaned. Another exterior feature provided in this example embodiment is a mesh layer which may serve as a pocket 1302 and may be affixed onto the outermost exterior surface of an upper front face 928 of the unit via adhesives, heat fusion, stitching, and/or a combination thereof.
In one embodiment, the inflatable unit may comprise an insulation layer comprising an aluminum foil bubble material that may be disposed between PVC layers along each long side of the unit. For example, in at least one embodiment, the foam lined layer 1002 of the unit may be replaced with an aluminum foil bubble material. In this way, the storage compartment may be further insulated from exterior conditions and the reflective nature of the aluminum foil may reduce radiant thermal transfer.
In at least one embodiment, the zipper assembly 918 may comprise a No. 10 large tooth all plastic zipper. In some examples, the zipper assembly 918 may further comprise t shaped pull handles that may be constructed from plastic or other suitable lightweight and resilient materials.
An example technical effect of constructing the unit with a single inflatable chamber is that the speed and ease of inflation and deflation may be improved because there may be a single air valve as opposed to one for each section of the inflatable chamber. This may allow for quickly deflating and collapsing the unit to be stored when not in use, as well as quickly inflating the unit prior to its use. Further, when the unit is deflated, it may collapse into a substantially thinner profile than that of the fully inflated unit body and may be further compressed since the drop-stitch fabric used in the chamber construction may be flexible when not inflated. In this way, the portability of the unit may be greatly supplemented. An example technical effect of positioning the inflation air valve 906 on the exterior surface of the unit may be to allow for quick and easily accessible inflation and deflation of the unit body. With the air valve placed on the exterior, the unit may not have to be opened or closed prior to inflation or deflation of the chamber.
Turning now to
The inflatable unit 1500 also includes a plurality of sides. Each of the sides extends between the top portion 1504 and the bottom portion 1502. The sides and the top and bottom portions form boundaries of an interior storage compartment, such as the storage compartments described with regard to the other unit embodiments. The sides can be conceptual divided into pairs and in the depicted embodiment the inflatable unit 1500 includes four sides. However, other inflatable unit 1500 layouts have been contemplated such as unit having less or more than four sides, such as a unit with three sides or six sides, for instance. The inflatable unit 1500 therefore includes a first pair of sides 1508 with a first side 1510 and a second side 1512. The inflatable unit 1500 additionally includes a second pair of sides 1514 with a third side 1516 and a fourth side 1518. The first side 1510 and the second side 1512 are positioned to oppose one another. Likewise, the third side 1516 and the fourth side 1518 are positioned to oppose one another. The inflatable unit 1500 has a trapezoidal shape in the depicted embodiment. However, other unit shapes have been contemplated. In the depicted example, the first side 1510 and the second side 1512 have a similar boundary profile. That is to say the shape of the peripheral regions of the first and second sides of the unit may be substantially identical. Likewise in the depicted example, the third side 1516 and the fourth side 1518 have a similar boundary profile. It will be appreciated that in some instances each side may include different accessories such as pockets, attachment features, valves, etc., and that sides with varying geometries have also been contemplated.
The inflatable unit 1500 may be set in an expanded or condensed configuration based on a user's predilection. In
Now specifically referring to
In another example, the inflation chamber 1522 may be included in the first pair of sides 1508 and the second pair of sides 1514. In yet another example, the inflation chamber 1522 may only be included in the second pair of sides 1514. In such an example, the first pair of sides may include foam or other forms of insulation material. Inflating the inflation chamber 1522 may move the inflatable unit 1500 include the expanded configuration, shown in
The first pair of sides 1508 includes a plurality of foldable sections 1528 that enable the sides of the unit to be arranged in the expanded configuration shown in
Continuing with
Additionally, in
In one example, the inflatable unit may be more generally referred to as an article of manufacture and may have other uses beyond storing contents at a low temperature, such protecting interior contents or other conceivable uses. The inflatable unit 1500 shown in
In one example, the first pair of sides may include a first side opposing a second side and the second pair of sides includes a third side opposing a fourth side and where the inflation chamber is included in the first and second pairs of sides. In another example, when the first pair of sides is in the condensed configuration, the inflation chamber may be at least partially deflated and the plurality of foldable sections is creased. In yet another example, when the first pair of sides is in the expanded configuration, the first pair of sides may be substantially vertically oriented.
It will be appreciated that the configurations and methods disclosed herein are exemplary in nature, and that theses specific embodiments are not to be considered in a limiting sense, due to the possibility of numerous variations. For example, the above technology may be applied to various shapes, other units, or to other storage devices. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various methods and configurations and other features, functions, and/or properties disclosed herein.
In another aspect, an inflatable unit may comprise one or more of a first unit body face comprising drop-stitch material, a second unit body face comprising drop-stitch material, and a storage compartment defined by the first and second unit body faces. In this or any of the above aspects or subcombinations thereof, the first unit body face and second unit body face are nonreleasably coupled to each other at a bottom. In this or any of the above aspects or subcombinations thereof, the first unit body face and second unit body face are releasably coupled via a zipper at a top. In this or any of the above aspects or subcombinations thereof, the first unit body face is defined by a portion of a first inflatable chamber, and the second unit body face is defined by another portion of the first inflatable chamber. In this or any of the above aspects or subcombinations thereof, the first unit body face and the second unit body face are defined by a single, common inflatable chamber. In this or any of the above aspects or subcombinations thereof, inflatable unit further comprises a flexible set of handles.
In another aspect, an inflatable and deflatable unit may comprise one or more of a first section comprising at least four vertical walls forming a trapezoidal-end-sided and rectangular-side-sided interior chamber, where each wall only partially comprises drip-stitch construction and having a common inflatable chamber; and a bottom section, the bottom section having an interior fluidically connected with the common inflatable chamber, where drop stitches are positioned in the bottom section, the drop stitches vertically positioned; and a layer wrapping together the first section and the bottom section. In any of the above aspects or subcombinations thereof, the unit further comprises a zipper closure to fully close the interior chamber and/or only a portion of the bottom section comprises drop-stitch construction. In any of the above aspects, the portions having drop-stitching may form a structural frame for the unit, with remaining surfaces and/or walls without drip-stitching may be supported by the frame elements to form the overall unit. In any of the above aspects, an internal thermally reflective liner may be provided to fully cover one or more or each of the internal surfaces, both over areas with and without drop-stitching.
In an example, any of the units described herein, such as in the first embodiment, can be stacked upon one another. In an example, a system of units are stacked for shipping, for example vertically stacked where a bottom of a bottom wall of one unit is stacked upon (e.g., in face-sharing contact) a top of a lid of another identical unit.
The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
The present application is a continuation-in-part of continuation-in-part application Ser. No. 15/401,933 entitled “DROP-STITCH INFLATABLE COOLER,” filed Jan. 9, 2017. Application Ser. No. 15/401,933 is a continuation-in-part of International Application No. PCT/US2016/21851 entitled “DROP-STITCH INFLATABLE COOLER”, filed Mar. 10, 2016. International Application No. PCT/US2016/021851 claims priority to U.S. Provisional Patent Application No. 62/131,623 entitled “DROP-STITCH INFLATABLE COOLER”, filed Mar. 11, 2015, and U.S. Provisional Patent Application No. 62/255,245 entitled “COLLAPSIBLE DROP-STITCH INFLATABLE COOLER”, filed Nov. 13, 2015. The entire contents of the above-referenced applications are hereby incorporated by reference for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62131623 | Mar 2015 | US | |
| 62255245 | Nov 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15401933 | Jan 2017 | US |
| Child | 17068560 | US | |
| Parent | PCT/US2016/021851 | Mar 2016 | US |
| Child | 15401933 | US |
