Patent Application
20090193838
Embodiments of the present invention relate to an insulating apparatus and a process for manufacturing the insulating apparatus. Specifically, the embodiments of the present invention include a cooler or warmer with removable thermal adjustment units such as freezer or heating packs.
Coolers are commonly used for storing perishable food and beverage items. Coolers are suitable for use in numerous environments, including sporting events, social outings, catering events, and work settings. Coolers provide refrigeration, so that food and beverage items can be stored for an extended period of time period before spoiling.
In certain settings, it is desirable to refrigerate food and beverage items in the cooler to maintain the freshness of these items before they are consumed. Typically, ice is used as a refrigerant for the cooler to keep the temperature in the cooler low. An alternate solution is to forgo ice usage by refrigerating or freezing the food and beverage items before placing them in the cooler. However, this solution requires preparation by refrigerating or freezing the items prior to the time they are to be placed in the cooler. Such preparation time is often unavailable. Also, many items do not freeze well, such as beverages in cans. Therefore, in most cases, ice is the solution for providing refrigeration. One disadvantage of using ice is the residual liquid collected from melted ice that may immerse food and beverage items in the cooler. Melted ice water also introduces problems for disposing of the liquid in a sanitary manner.
A cooler is a box shaped structure defining an inner chamber to hold food and beverage items. The walls of the cooler are insulated to maintain a temperature within the chamber. A cooler includes a handle to lift the cooler. However, the volume of ice required to provide refrigeration adds significant weight to the cooler and makes it more difficult to transport. The insulated walls are impermeable trapping melted ice water. After extended use, the ice providing refrigeration will melt and the food and beverage items are submerged in the water.
Embodiments of invention include an insulating apparatus and a process for manufacturing the insulating apparatus. In one embodiment, the insulating apparatus defines a set of internal compartments to hold a set of removable thermal adjustment units. The temperature of the interior of insulating apparatus can be regulated by the set of removable thermal adjustment units. A suitable refrigerant or heating compound is used within the removable thermal adjustment unit to regulate the temperature. A set of removable trays may also be inserted into the insulating apparatus to store beverages or similar items. A lid of the insulating apparatus forms a seal over an opening to the interior of the insulating apparatus. A custom graphic can be applied to the lid and/or the exterior of the insulating apparatus.
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean “at least one.”
s are diagrams of one embodiment of an insulating apparatus with removable thermal packs, lid and removable tray.
In the following detailed description of embodiments of the invention, reference is made to the accompanying drawings in which like references indicate similar elements, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical, functional, and other changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims. It will be apparent to one of ordinary skill in the art that the embodiments may be practiced without some of these specific details. In other instances, certain structures and devices are omitted or simplified to avoid obscuring the details of the various embodiments.
The insulating apparatus including removable thermal adjustment units is described in relation to example embodiments, such as a cooler with removable freezer packs. One skilled in the art would understand that the principles, features and structures of these example embodiments are applicable to other embodiments. Specific examples are utilized for sake of clarity and are not intended to limit the scope of invention. While the embodiment of a cooler with removable freezer packs is primarily discussed, the same principles, techniques and structures can be modified to provide a warming unit that includes removable heat packs. The insulating apparatus in this embodiment is used to maintain a warm or heated storage compartment. The presented cooler embodiment maintains a cool or refrigerated storage compartment. One skilled in the art would understand that these and similar modifications are enabled by the following description.
The cooler can have any size or dimensions that can define a compartment to hold items. In one embodiment, the outer diameter of the cooler may range from 0.5′ to 5′ and the height of the cooler may range from 0.5′to 5′. The dimensions of the storage compartment can range from a diameter of 0.5′ to 4.75′. Any number of compartments 150 can be defined by a set of radial walls 155. The set of compartments can have any size and dimensions suitable for receiving and securing freezer packs 165.
In one embodiment, removable freezer pack 165 may include handle 160 coupled at one end to facilitate removal from and insertion into one of the set of compartments within the cooler. Removable freezer pack 165 refrigerates the storage compartment 190 of the cooler. In one embodiment, tray 140 is disposed within the storage compartment 190 and is removably coupled with inner wall 130 of the cooler. Inner wall 130 forms a lip to support tray 140 and provides a form fit with tray 140 or similarly supports tray 140. In this manner, tray 140 can be disposed in the cooler for storage. Tray 140 defines a set of apertures or recesses for holding beverages, an item with a frusto-conical shape (e.g., a cup) or similarly shaped items. Once the items are placed in tray 140, removable freezer pack 165 provides refrigeration of the items located in tray 140.
In one embodiment, handle 110 and a movement mechanism 120 are attached to outer wall 100 of the cooler to facilitate transportation of the cooler. Handle 110 can have any size or dimensions suitable for managing the movement of the cooler. In one embodiment, handle 110 is a telescoping handle to allow adjustment of the length of handle 110. The transportation mechanism 120 can be a set of wheels, rollers, skis or similar mechanisms to facilitate the movement of the cooler over various surfaces.
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In one embodiment, the material used to adjust the interior temperature of the insulating apparatus or cooler is a refrigerant compound with a specific heat higher than that of typical ice (i.e., frozen water). The refrigerant compound may be any material suitable for performing an endothermic reaction that absorbs heat energy. In one embodiment, the refrigerant compound stored in thermal adjustment unit is a non-toxic polymer gel based on a mixture of several compounds such as cornstarch, borax, preservatives, and water. The non-toxic polymer gel is prepared for use by lowering the temperature of the non-toxic polymer gel. In one embodiment, any suitable process for freezing or refrigerating the non-toxic polymer gel is used. In another embodiment, the refrigerant compound is a mixture of polymer crystals and water prepared for use in a similar manner as described above. After thermal adjustment unit is placed within the cooler's interior, thermal adjustment unit lowers the temperature of the cooler's interior during the progression of the endothermic reaction by absorbing heat energy contained within the cooler's interior. In addition, because the refrigerant compound has a higher specific heat than of ice as described above, thermal adjustment unit maintains the lower temperature of the storage compartment inside the cooler for a longer time period than using ice alone because more heat energy is required to transition the refrigerant compound back into a liquid state. In one embodiment, the refrigerant compound may be reused by being refrozen or refrigerated again.
In another embodiment, the material inside of thermal adjustment unit may comprise a heating compound to adjust the interior temperature of the cooler. The heating compound may be any suitable compound used to increase the temperature of the cooler's interior through an exothermic reaction. In one embodiment, thermal adjustment unit is prepared for use by raising the temperature of the heating compound. Any suitable process for raising the temperature of the heating compound may be used. In the case of the sodium acetate solution, the exothermic reaction is performed by nucleation of the solution that causes the sodium acetate to crystallize. In one embodiment, a metal disc contained within thermal adjustment unit may be mixed with the sodium acetate solution to commence the exothermic reaction. During the exothermic reaction, heat energy is released that increases the interior temperature of the cooler. By placing thermal adjustment unit in the cooler's interior, the interior temperature of the cooler may be maintained at a higher temperature than without thermal adjustment unit. In one embodiment, thermal adjustment unit containing the heating compound may be reused by heating thermal adjustment unit to the boiling temperature of water. In the case of the sodium acetate solution, boiling thermal adjustment unit has the effect of dissolving the crystallized sodium acetate back into a liquid state.
The cooler can have any size or dimensions that can define a storage compartment to hold items. In one embodiment, the length and width of outer wall 500 of the cooler each ranges from 1′ to 5′ and the height of the cooler ranges from 1′ to 4′. The dimensions of the storage compartment can range from a length and width of 0.5′ to 4.75′ and a height from 0.75′ to 4′. The set of compartments can have any size and dimensions suitable for receiving and securing removable freezer packs 540 or other similar removable thermal adjustment units. Inner wall 535 forms a lip to support tray 520 and provides a form fit with tray 520 or similarly supports tray 520. In this manner, tray 520 can be disposed in the cooler for storage and removably coupled with inner wall 535. Tray 520 defines a set of apertures or recesses for holding beverages or an item with a frusto-conical shape (e.g., a cup). Once the items are placed in tray 520, removable freezer pack 540 provides refrigeration of the items located in tray 520.
Outer wall 500, side wall 525, and inner wall 535 may be formed from materials including, but not limited to, plastics (e.g., polyethylene, polycarbonate, polypropylene, polystyrene, or acrylonitrile butadiene styrene), metals (e.g., aluminum, steel, tin, or chrome), composite compounds (e.g., carbon fiber), and other resilient and lightweight materials. Materials may be selected for their insulating properties. The insulating properties of inner wall 525, side wall 525, and outer wall 500 protect the storage compartment from temperature and environmental conditions outside of the cooler. In this manner, the temperature of the storage compartment is regulated by the set of freezer packs 540. In addition, outer wall 500, side wall 525, and inner wall 525 can be formed by any process including molding, extrusion, welding or similar assembly techniques.
In one embodiment, removable freezer pack 540 may include handle 530 coupled at one end to facilitate removal from and insertion into one of the set of compartments within the cooler. Removable freezer pack 540 refrigerates the storage compartment of the cooler.
In one embodiment, handle 550 and a movement mechanism 560 are attached to outer wall 500 of the cooler to facilitate transportation of the cooler. Handle 550 can have any size or dimensions suitable for managing the movement of the cooler. In one embodiment, handle 550 is a telescoping handle to allow adjustment of the length of handle 550. The transportation mechanism 560 can be a set of wheels, rollers, skis or similar mechanisms to facilitate the movement of the cooler over various surfaces.
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The thermal adjustment units are then inserted or attached to their respective placements within the insulating apparatus (block 820). A set of thermal adjustment units is placed in the set of compartments between the inner and outer walls of the insulating apparatus. In one embodiment, a bottom thermal adjustment unit is placed or attached to the bottom of the storage compartment. A top thermal adjustment unit is attached to the lid. Any securing mechanisms such as screws, brackets or similar mechanisms can be used to secure the top and bottom thermal adjustment units. In another embodiment, the top and/or bottom thermal adjustment units are omitted from the insulating apparatus.
The tray is inserted into the insulating apparatus (block 830). In one embodiment, the tray is form fitted to be rest upon on a lip defined by the inner wall of the insulating apparatus. In another embodiment, the tray includes a set of latches, fasteners, clips, or similar mechanism for securing the tray to the inner wall of the insulating apparatus.
The handle is then mounted to the outer wall of the insulating apparatus (block 835). Any suitable securing mechanism including screws, brackets, fasteners, or similar mechanisms can be used to secure the handle to the insulating apparatus. The handle can be mounted in any suitable position on the outer wall of the insulating apparatus. In one embodiment, the handle can be mounted at a position distal to a bottom wall of the insulating apparatus.
Next, the transportation mechanism is mounted to the outer wall of the insulating apparatus (block 840). The transportation mechanism can be a set of wheels, skis, rollers, ball bearings, or similar mechanisms to facilitate the movement of the cooler over various surfaces. In one embodiment, the transportation mechanism is mounted at a position distal to the handle.
The insulating apparatus and lid are then decorated (block 850). In one embodiment, a graphic is applied to the outer wall of the insulating apparatus and top portion of the lid using a silk screening process, adhesive decal, or other similar printing technique. The top portion of the lid may include padding covered in upholstery that can be decorated using embroidery, cloth patching, pattern dying, staining, or other suitable upholstery decorating technique. In another embodiment, decoration on the insulating apparatus and lid are omitted.
Finally, the lid is attached to an open portion of the insulating apparatus. Any suitable mechanism such as a flange, fastener, rubber ring, latch, clip, or similar mechanism may be used to attach the lid to the insulating apparatus. In one embodiment, the lid includes a rubber ring or similar mechanism to form an air tight or water tight seal with the insulating mechanism.
The embodiments of the present invention have been described largely by reference to specific examples illustrated in the figures and described above. However, those of skill in the art will appreciate that alternatives and modifications of the embodiments of this invention will become apparent to those skilled in the art without departing from the scope of this invention. Such variations and implementations are understood to be captured according to the following claims.
