SOFT-SIDED CONTAINER

Abstract

A soft sided insulated container having a bladder incorporated into a continuous sidewall. The bladder includes a spacer and a mechanism to remove excess air, allowing increased insulative properties and adjusting of the sidewall thickness. A one-way air valve is fluidly coupled to the bladder, allowing an individual to pull air from the bladder.

Description

FIELD OF THE INVENTION

This invention relates to the field of soft-sided containers and, in particular, to a soft sided container with increased insulative properties.

BACKGROUND OF THE INVENTION

Soft-sided containers are well known in the industry. Soft-sided containers commonly include a fabric or TPU wall covering, providing impact advantages over hard-sided containers. Soft-sided containers may be non-insulated containing no thermal barrier, or insulated, wherein a thermal barrier is placed between an inner and outer wall. Hard-sided insulated containers have an inner wall separated from an outer wall by an insulation material and/or spacing.

A soft-sided insulated container relies on an external insulated wall structure that is not substantially rigid. The sidewall may be foldable between a collapsed and an expanded configuration. The wall structure includes an outside layer of TBU material, webbing or fabric, an inside layer of TBU material, webbing or fabric, and a layer of flexible insulation therebetween, positioned between the inner and outer layers. Soft-sided coolers sometimes include substantially rigid liners to assist in permitting the cooler to maintain a given shape, or to protect items inside the cooler from being crushed.

Soft-sided containers can be made to fold, making it easier to fit into a sized opening for compact storage when not in use. The lid of a soft-sided container relies upon a zipper or hook & loop material for closure, the closure mechanism covering three of the four side walls, the fourth side being hinged. Even if insulated, the soft sides can be made to compress into a small footprint, making storage more convenient. Further, if a soft-sided container impacts another object, damage can be avoided since the soft-sided container operates as the give-way object, thereby absorbing the impact forces. For instance, a soft-sided insulated container is preferred by astute boat owners since the movement on a boat will likely cause the insulated cooler to move and impact part of the boat. Having a soft-sided shell on the insulated container reduces or eliminates damage to the boat, as the container will absorb the damaging forces. In addition, soft-sided containers are generally lightweight and can be made both durable and attractive. While the soft-sided container has numerous advantages, a disadvantage is the insulating properties. Unlike rigid-sided containers, the soft-sided walls can separate from the insulating barrier, lessening the insulating ability.

U.S. Pat. No. 5,918,478 discloses an insulated chest for storage of perishable goods which require a temperature-controlled environment. The chest includes insulated side walls, bottom and a hinged cover which is pneumatically sealed to prevent tampering and for thermal security. The chest includes a fluid conduit within the cover for air evacuation and depressurization of the interior, and also includes a conduit to provide a vacuum between the walls of the sides and bottom which contain a rigid polymeric foam insulation.

U.S. Pat. No. 6,510,946 discloses a vacuum insulated lunch box comprised of a top half and a bottom half, the top half and bottom half each having a double wall construction, the top half and bottom half each having an outlet check valve, and the outlet check valves each capable of receiving a tube from a vacuum pump for the purpose of evacuating the cavity of each said lunch box half. An embodiment includes a built in vacuum pump.

U.S. Pat. No. 9,668,510 discloses a cooler with an insulated housing comprising an encircling wall, base and lid, the insulated housing defining a storage cavity and having an air channel communicating from the storage cavity to outside the insulated housing; the air channel being defined by channel walls and forming at least in part a cylinder. A vacuum pump is integral with the insulated housing; the vacuum pump comprising a piston arranged to reciprocate within the cylinder under manual control from outside of the insulated housing. The vacuum is used to reduce the air pressure within the storage cavity.

U.S. Publication 2008/0223862 discloses a cooler with inflatable sidewalls. The cooler comprises a base and an insulated container defining a cooler. The container includes an inflatable wall and a valve for inflating of the wall. The insulated container is removably coupled to the base, and the base defines a container receiving recess within which a bottom portion of the insulated container is received. When the portable cooler assembly is in a first configuration, the inflatable wall is inflated and extends outwardly from the container receiving space. When the portable cooler assembly is in a second configuration, the inflatable wall is deflated and is completely received within the container receiving space in a collapsed condition.

U.S. Publication 2008/0260303 discloses insulated shipping bags. In this disclosure, a collapsible insulated bag is designed to allow items retained within an inner pouch thereof to remain within predetermined temperature ranges for predetermined periods of time, and wherein the bags are designed to be easily compressed or compacted for storage or shipment to end users. The bags include at least an outer reflective layer, an intermediate open foam layer, and the inner pouch layer.

U.S. Publication 2010/0310194 discloses a handheld electronic device enclosure which includes a flexible bag having an interior cavity for enclosing the handheld electronic device and an opening for insertion of the device into the bag cavity, a closure for releasably sealing the bag opening, and a sealable exhaust tube extending from the bag cavity to the exterior of the bag for use in evacuating air from the bag cavity when the opening is sealed. The tube preferably includes a one-way valve, allowing air to flow from the bag cavity, but not into the bag cavity. A detachable means, such as a rubber bulb, may be included to withdraw air from the cavity through the tube. The case may also include an electronic jack extending from the bag cavity to the exterior of the bag.

U.S. Publication 2014/0248003 discloses a soft-sided insulated container with inflatable wall structure. The insulated container assembly is made of a flexible wall structure that is movable between a collapsed position and a deployed position. In one variation of the deployed position, it resembles a tote-bag; in another variation of folding, the deployed position corresponds to a generally box-like shape. The container includes a self-inflating wall structure that has an inner layer or skin, an outer layer or skin, and a resilient, open-cell insulating layer trapped between the two skins. A valve governs the ability to take in or to expel air. The outer layer may be thicker and more robust than the inner layer, the better to resist abrasion or punctures. The inner layer may be reflective. There may be a removable internal liner, which may be transparent.

What is lacking in the industry is a soft-sided insulated container including a vacuum assist assembly to increase the insulating properties of the container and adjust the thickness of the container wall.

SUMMARY OF THE INVENTION

Disclosed is a vacuum assist assembly that is securable to a wall of a soft-sided container. The container comprises a body defining a chamber therewithin. A cover is positionable over an upper edge of the body, with a zipper mechanism securing access to the insulated chamber when the cover is in a closed position, and allowing access to the insulated chamber when said cover is in an open position. The vacuum assist assembly consists of an air valve that is in fluid communication with either a bladder placed between two material side walls, or a bladder formed by placing an impermeable coating on an interior surface of the two material side walls; the bladder defining an interior space for placement of an insulating material or spacer. A partial vacuum can be pulled on the bladder by withdrawing air through the air valve. A one-way flapper allows air to be withdrawn only from the bladder. The insulating material can simply be a spacer, such as EVA or EPE foam, wherein a controlled space operates to increase the insulating ability of the container side walls. Alternatively, the insulating material may include thermal properties, such as polyurethane, which is able to repel heat and cold. Critical to this invention is the drawing of the bladder sidewall tightly against the spacer, the bladder having controlled spacing that increases the thermal properties of the insulating material.

An objective of the invention is to increase the insulating effects in a soft-sided container.

Still another objective of the invention is to provide a valve that allows fluid to be removed from a bladder chamber if the interior liner is punctured, prior to repairing the puncture.

Still another objective of the invention is to provide a one-way valve that allows drawing of a vacuum and inhibits air from repopulating the bladder chamber.

Yet another objective of the invention is to provide a continuous bladder to allow the four walls, and optionally a lid of the container, to have a partial vacuum drawn through a single point air valve.

Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front plane view of a container without wheels;

FIG. 2 is a cross sectional view of a wall with a bladder;

FIG. 3 is a cross sectional view of a wall with non-permeable walls as an alternative embodiment;

FIG. 4 is a perspective view of the air valve;

FIG. 5 is a front view thereof;

FIG. 6 is a rear perspective view thereof;

FIG. 7 is a rear view thereof; and

FIG. 8 is an exploded cross sectional view of the air valve.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Detailed embodiments of the instant invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

Referring to FIG. 1, illustrated is a container 100 to illustrate the applicability of the invention to most any style soft sided container. In this illustration, the container 100 has a base 102 formed from a rigid material; and a continuous sidewall 104 having a lower end 103 secured to the base 102, the base 102 defining a shape of the sidewall 104. The sidewall 104 in this embodiment can be further defined as a front surface 114, a rear surface 115 and two side surfaces 117, 119. The sidewall 104 forms an interior storage chamber, not shown, for the temporary placement of items to be chilled. An upper portion, or cover, 106 of said sidewall 104 is used to seal the interior chamber, and is formed from a flap 107 with an end 108 securable to the front of the sidewall 104 by a clasp mechanism 120. Release of the clasp mechanism 120 allows the upper portion 106 to be moved upwardly, allowing access to the interior, not shown. The sidewall 104 may include a frontal handle 110 and a cover handle 112 for ease of movement. In this embodiment, the air valve 50 has a cylindrical shaped body 90 with an opening to the interior of a bladder formed within the continuous sidewall 104. The air valve 50 is protected and further sealed by a cap 92 that frictionally engages the air valve 50. The air valve 50 can be attached to the front, rear or side surface.

Now referring to FIG. 2, the sidewall 104 is formed from an outer flexible wall 52 and a plastic flexible inner wall 54. A bladder 56 formed from a non-permeable thin wall plastic is positioned between the materials 52, 54, and is sealed except for an access port formed by the air valve 50. For illustrative purposes, only a cutaway of a portion of the sidewall 104 is depicted. The remaining sidewall 104 and cover 106 can be constructed similarly, with the preferred embodiment having a continuous bladder, or interconnected bladders. In a preferred embodiment, a single bladder is employed with the objective being the use of a single air valve for drawing a partial vacuum of air from the bladder which surrounds the interior chamber.

Inside the bladder 56 is a spacer material 58 which includes thermal, structural or insulative properties. For instance, a spacer material 58 may be constructed from felt, wherein drawing a partial vacuum provides a predefined space between adjoining walls of the bladder 56; the spacing creating an insulating barrier. Alternatively, the spacer material 58 may be constructed from EVA or EPE foam, wherein drawing a vacuum provides a predefined space between adjoining walls of the bladder 56, and the foam provides inherent thermal properties. Still another example is the use of expanded flexible foam having inherent thermal properties.

Now referring to FIG. 3, in an alternative embodiment, the sidewall 125 is formed from an outer flexible wall 60 having an inner surface 62 and an outer surface 64, and an inner wall 66 having an inner surface 68 (not labeled on FIG. 3) and an outer surface 70. In this embodiment, the inner surfaces 62, 68 are coated with a non-permeable composition such as a plasticizer. The outer flexible wall 60 and the inner flexible wall 66 are sealed together along a common edge, forming an interior space 72 for placement of a spacer material 74. Similar to the previous embodiment, the spacer material 74 may include insulating properties that improve the insulating characteristics of the storage chamber by spacing the outer wall 60 from the inner wall 66. For illustrative purposes, only a cross section portion of the wall 125 is depicted. The remaining sidewall 125 and cover 106 can be constructed similarly with the formed bladders positioned in each wall in fluid communication with adjoining bladders, an objective being the use of a single air valve 50 for drawing a partial vacuum on the interior space of the bladder(s). To help maintain a pulled vacuum, the air valve 50 is formed from a body 90 having a sealing cap 92 held with a living hinge 94.

Referring to FIGS. 4-8, the air valve 50 has a cylindrical shaped body 90 with an opening 96 constructed and arranged to be sealed by the cap 92. The opening 96 has a base 95 with an outer surface 97 having a plurality of apertures 98 covered with a flexible flapper 100 leading to an inner surface 102. The flexible flapper 100 is preferably constructed from rubber and attached to the base 95 with a fastener 109. When secured to a bladder, the air valve 50 allows air to be drawn from the bladder by an individual drawing air through the air valve 50, wherein air passes through the apertures 98 extending through the inner surface 102, which displaces the flexible flapper 100 as air is being drawn from the bladder. Critical to this invention is the ability to cause the bladder side walls to adhere to the spacer material 58 or 74 which provide insulation properties when used in combination with the bladder. This improves the thermal capabilities of the insulation and provides the perception of a larger interior space with easier access. Air can be drawn from the air valve 50 by a pump or an individual can draw air directly from the bladder by pulling a suction on the air valve. In this manner, the isolative properties of the container can be adjusted to the individual's preference.

It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “has,” “includes” or “contains” one or more steps or elements, possesses those one or more steps or elements, but is not limited to possessing only those one or more elements. Likewise, a step of a method or an element of a device that “comprises,” “has,” “includes” or “contains” one or more features, possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed.

Claims

1. A soft-sided insulated container comprising: a rigid base;a continuous sidewall secured to said base and extending upwardly to an upper portion, said continuous sidewall defining a bladder, said upper portion constructed and arranged to fold, forming a storage chamber within said continuous sidewall;a spacer material placed within said bladder;an air valve attached to said bladder, said air valve having an aperture fluidly communicated with an interior space of said bladder, wherein said air valve is available for drawing air from said interior space of said bladder to adjust the insulative properties of the container;a clasp mechanism releasably securing said upper portion in a folded securing access to said storage chamber when said upper portion is in a closed position, and allowing access to said storage chamber when said upper portion is in an open position.

2. The soft-sided insulated container according to claim 1 wherein said air valve is further defined as a flexible flapper constructed and arranged to seal said aperture, wherein said flapper allowing excess air to be removed from said interior space of said bladder.

3. The soft-sided insulated container according to claim 1 wherein said bladder is constructed from a continuous wall of non-permeable material defining an interior space.

4. The soft-sided insulated container according to claim 1 wherein said spacer material includes thermal insulating properties.

5. The soft-sided insulated container according to claim 4 wherein said spacer material is fiberglass.

6. The soft-sided insulated container according to claim 4 wherein said spacer material is foam rubber.

7. The soft-sided insulated container according to claim 1 wherein said upper portion is creased at a predetermined position, forming a living hinge.