Note: Descriptions are shown in the official language in which they were submitted.
84935024
INSULATING DEVICE
Cross-Reference Section
[01] This application claims priority to U.S. Application No. 15/154,626,
filed on May 13,
2016. U.S. Application No. 15/154,626 is a continuation-in-part of U.S.
Application
No. 14/831,641, filed on August 20, 2015, which is a divisional application of
U.S.
Application No. 14/479,607 filed on September 8, 2014, now U.S. Patent No.
9,139,352, which claims priority to U.S. Application No. 61/937,310 filed on
February
7, 2014.
Field
1021 The present disclosure relates generally to non-rigid, portable,
insulated devices or
containers useful for keeping food and beverages cool or warm, and, more
particularly,
an insulating device with a waterproof closure.
Background
[03] Coolers are designed to keep food and beverages at lower temperatures.
Containers
may be composed of rigid materials such as metal or plastics or flexible
materials such
as fabric or foams. Coolers can be designed to promote portability. For
example, rigid
containers can be designed to incorporate wheels that facilitate ease of
transport or
coolers can be designed in smaller shapes to allow individuals to carry the
entire device.
Non-rigid containers can be provided with straps and/or handles and may in
certain
instances be made of lighter weight materials to facilitate mobility. Non-
rigid coolers
that maximize portability can be designed with an aperture on the top that
allows access
to the interior contents of the cooler. The aperture can also be provided with
a closure.
Summary
[04] This Summary provides an introduction to some general concepts relating
to
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this invention in a simplified form that are further described below in the
Detailed
Description. This Summary is not intended to identify key features or
essential features
of the invention.
[05] Aspects of the disclosure herein may relate to insulating devices having
one or more of
(1) a waterproof closure (2) an outer shell, (3) an inner liner, (4) an
insulating layer
floating freely in between the outer shell and the inner liner, or (5) a
waterproof storage
compaitment.
[05a] According to one aspect of the present invention, there is provided an
insulating device
having a front, a rear, and a base, wherein the insulating device is
configured to stand
upright from the base, comprising: an outer shell defining a sidewall and the
base, the
outer shell having a front portion and a rear portion; an inner liner forming
a storage
compaitment, the inner liner having a front portion and a rear portion;
wherein top
portions of the front and rear portions of the outer shell and the front and
rear portions
of the inner liner are connected by a joint; an insulating layer positioned in
between the
outer shell and the inner liner, the insulating layer providing insulation for
the storage
compaitinent; a vertically extending front facing surface on the front of the
insulating
device; an opening located on the front facing surface configured to allow
access to the
storage compaitinent; and a closure located on the front facing surface
adapted to
substantially seal the opening, the closure being substantially waterproof so
as to resist
liquid from exiting the opening when the insulating device is in any
orientation; wherein
the insulating layer has a first height extending from the base and a second
height
extending from the base, wherein the first height is greater than the second
height, and
the insulating layer in the front of the insulating device extends to the
second height and
the insulating layer in the rear of the insulating device extends to the first
height.
105b] According to another aspect of the present invention, there is provided
a method of
forming an insulating device having a front, a rear, a base having a bottom
perimeter,
and a vertically extending front facing surface comprising: forming an inner
liner the
inner liner defining a storage compaitment, the inner liner having a front
portion and a
rear portion; forming an outer shell defining a sidewall, the outer shell
having a front
portion and a rear portion; placing an insulating layer comprising a first
portion and a
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base portion, wherein the base portion is located in the base of the
insulating device, in
between the outer shell and the inner liner, the insulating layer providing
insulation for
the storage compai __ intent, wherein the first portion of the insulating
layer has a first
height and a second height, wherein the first height is greater than the
second height,
and the first portion of the insulating layer in the front of the insulating
device extends
to the second height and the first portion of the insulating layer in the rear
of the
insulating device extends to the first height; connecting top portions of the
front and rear
portions of the outer shell and the front and rear portions of the inner liner
with a joint;
placing an opening on the front facing surface in the inner liner and the
outer shell; and
placing a closure on the front facing surface between the inner liner and the
outer shell,
the closure adapted to substantially seal the opening, the closure being
substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device is
in any orientation.
Brief Description of the Drawings
[06] The foregoing Summary, as well as the following Detailed Description,
will be better
understood when considered in conjunction with the accompanying drawings in
which
like reference numerals refer to the same or similar elements in all of the
various views
in which that reference number appears.
[07] Fig. lA shows a left front perspective view of an example insulating
device in
accordance with an aspect of the disclosure;
[08] Fig. 1B shows a frontside perspective view of the example insulating
device of Fig. lA
without the shoulder strap;
[09] Fig. 2 shows a backside perspective view of the example insulating device
of Fig. 1A
without the shoulder strap;
[10] Fig. 3A shows a top perspective view of the example insulating device of
Fig. lA
without the shoulder strap;
[11] Fig. 3B shows atop view of a portion of the example insulating device of
Fig. 1A;
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[12] Fig. 3C shows a portion of an alternate top perspective view of the
example insulating
device of Fig. 1A;
[13] Fig. 4 shows a bottom perspective view of the example insulating device
of Fig. 1A;
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[14] Fig. 5A illustrates a schematic of a cross-sectional view of the example
insulating device
of Fig. 1A;
[15] Fig. 5B illustrates another schematic of an enlarged portion of a cross-
sectional view of
the example insulating device of Fig. 1A;
[16] Fig. 6 illustrates an exemplary process flow diagram for forming an
insulating device;
[17] Figs. 7A-7J illustrate exemplary methods of forming an insulating device;
[18] Figs. 8A and 8B depict perspective views of an alternative example
insulating device.
[19] Fig. 9 depicts a portion of an exemplary closure and an example test
method for
determining if an insulating device maintains the contents therein.
[20] Fig. 10 depicts an example test for determining the strength of an
insulating device.
[21] Fig. 11 shows a front view of another exemplary insulating device.
[22] Fig. 12 shows a side view of the exemplary insulating device of Fig.
11.
[23] Fig. 13 shows a front perspective view of the exemplary insulating device
in an alternate
configuration.
[24] Fig. 14A shows a side and cross-sectional view of the exemplary
insulating device of Fig.
11.
[25] Fig. 14B shows an enlarged section of Fig. 14A.
[26] Fig. 15 shows a schematic exploded view of an exemplary insulation layer
for the
example insulating device of Fig. 11.
[27] Fig. 16A shows a portion of another example insulating device.
[28] Fig. 16B shows a side view of the example insulating device of Fig. 16A.
[29] Fig. 17 shows a perspective view of another example insulating device.
[30] Fig. 18 shows a front view of the insulating device of Fig. 17.
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[31] Fig. 19 shows a rear view of the insulating device of Fig. 17
[32] Fig. 20 shows a side view of the insulating device of Fig. 17.
[33] Fig. 21 shows a cross-sectional view of the insulating device of Fig.
17.
[34] Fig. 22 shows a schematic exploded view of an exemplary insulation layer
for the
example insulating device of Fig. 17.
[35] Fig. 22A shows a front view of an exemplary insulation layer for the
example insulating
device of Fig. 17.
[36] Fig. 23 illustrates an exemplary testing method.
Detailed Description
[37] In the following description of the various examples and components of
this disclosure,
reference is made to the accompanying drawings, which form a part hereof, and
in which
are shown by way of illustration various example structures and environments
in which
aspects of the disclosure may be practiced. It is to be understood that other
structures and
environments may be utilized and that structural and functional modifications
may be
made from the specifically described structures and methods without departing
from the
scope of the present disclosure.
[38] Also, while the terms "frontside," "backside," "top," "base," "bottom,"
"side," "forward," and
"rearward" and the like may be used in this specification to describe various
example
features and elements, these terms are used herein as a matter of convenience,
e.g., based
on the example orientations shown in the figures and/or the orientations in
typical use.
Nothing in this specification should be construed as requiring a specific
three
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dimensional or spatial orientation of structures in order to fall within the
scope of the
claims.
[39] FIGS. 1-4 depict an exemplary insulating device 10 that can be configured
to keep
desired contents stored cool or warm for an extended period of time. The
insulating
device can generally include an outer shell 501, a closure 301, an insulating
layer 502,
and an inner liner 500. As shown in Fig. 3C, the inner liner 500 forms a
chamber or
receptacle 504 for receiving the desired contents therein. As shown in Fig.
1A, various
handles, straps, and webs (e.g. 210, 212, 218, 224) can also be included on
the insulating
device 10 for carrying, holding, or securing the insulating device 10.
[40] The insulating device 10 can be configured to keep desired contents
stored in the receptacle
504 cool or warm for an extended period of time. In one example, the
insulating
device 10 can also be designed to maintain water inside the inner chamber or
receptacle
504, and the insulating device 10 can be configured to be water "resistant"
from the
outside in. In other words, the insulating device 10 can be formed "water
tight" inside the
inner liner 500, and water cannot leak into the inner liner 500 from the
outside or out from
the inside of the inner liner 500 when the closure 301 is in the closed
position.
[41] Fig. 4 depicts a bottom view of the insulating device 10. As shown in
Fig. 4, the
insulating device 10 may include a base 215 and a base support ridge 400. The
base
support ridge 400 can provide structural integrity and support to the
insulating device 10
when the insulating device 10 is placed onto a surface.
[42] In one example, as shown in Figs. 3A and 4, the top of the outer shell
501 has a first
perimeter circumference (Teir) and the bottom of the outer shell 501 has a
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perimeter circumference or a base perimeter 401 (Bcir). The circumference of
the top of
the outer shell 501 can be equal to the circumference on the bottom when
folded into a
cylinder, and Bcir can be equal to Tcir. In one example, the first
circumference and the
second circumference can both have an oval shape to form an elongated or
elliptical
cylinder. In one example, the top outer layer 501a can have a length of 23.5
inches and a
width of 5.5 inches. Therefore, the length to width ratio of the top outer
layer 501a can
be approximately 4.3. Additionally, the base 215 can have a length of 20.0
inches and a
width of 12.25 inches. Therefore, the length to width ratio of the base 215 is
approximately 1.6. In this example, the length to width ratio of the upper
wall can be
greater than the length to width ratio of the base.
[43] In one example, as shown in Fig. 5A, the inner layer or inner liner 500
can be formed of a
top inner liner portion or first inner liner portion 500a, an inner layer mid
portion or
second portion 500b, and an inner layer bottom portion 500c. The top inner
liner portion
500a, the inner layer mid portion 500b, and the inner layer bottom portion
500c are
secured together, by for example welding, to form the chamber 504. The chamber
504
can be a "dry bag," or vessel for storing contents. In one example, after the
top inner
liner portion 500a, the inner layer mid portion 500b, and the inner layer
bottom portion
500c are secured or joined together, a tape, such as a TPU tape can be placed
over the
seams joining the sections of the chamber 504. The inner liner 500 can, thus,
either
maintain liquid in the chamber 504 of the insulating device 10 or prevent
liquid contents
from entering into the chamber 504 of the insulating device 10. In one
example, as will
be described in further detail below, the inner liner 500 can be suspended in
the insulating
device 10 by only the closure 301.
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[44] The insulating layer 502 can be located between the inner liner 500 and
the outer shell 501,
and can be formed as an insulator to assist in maintaining the internal
temperature of the
receptacle 504. In one example, the insulating layer 502 can be a free
floating layer that
is not attached directly to the outer shell 501 or the inner liner 500. The
insulating layer
502 can be formed of a first portion 502a and a second portion or base portion
502b. The
first portion 502a and the second portion 502b can be formed of an insulating
foam
material as will be described in further detail below.
[45] The first portion 502a can have a rectangular shape that maintains its
form when folded into
a cylinder and placed in between the inner liner 500 and the outer shell 501
and when
encased from above by the outer shell 501. The insulating layer 502 maintains
its shape
which results in the basic oval-cylindrical shape of the insulating device 10.
Therefore,
similar to the outer shell 501, the top of the insulating layer 502 has a
first perimeter
circumference, and the bottom of the insulating layer 502 has a second
perimeter
circumference. The first perimeter circumference of the insulating layer 502
can be equal
to the second perimeter circumference of the insulating layer 502.
[46] The base portion 502b can be included to provide additional insulation
along the insulating
device 10 at base 215. The base portion 502b can be formed as an oval shape to
close off
a lower opening 506 formed by the cylindrical shape of the insulating layer
502.
[47] Additionally, the bottom portion of the insulating device 10 can include
an additional base
support layer 505, which adds to the insulation and the structural integrity
of the
insulating device 10. The base support layer 505 may also provide additional
protection
around the bottom of the insulating device 10. In one example, the base
support layer
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505 can be formed from EVA foam. The base support layer 505 may include a
certain
design such as a logo or name that can be molded or embossed directly into the
material.
The base support ridge 400, which provides structural integrity and support to
the
insulating device 10 can also be molded or embossed directly into the base
support layer
505. In one example, the base support layer 505 and the base portion 502b can
be
detached for ease of assembly.
[48] The outer shell 501 can be formed of a top outer layer portion or first
shell portion 501a, an
outer layer or second outer shell portion 501b, and a bottom or third shell
portion
501c. The outer shell 501 provides a covering for the insulating device 10. In
one
example, the insulating layer 502 can be suspended freely within the outer
shell 501.
However, it is contemplated that any of the layers could be secured or formed
as a one-
piece integral structure. The outer shell 501 can be configured to support one
or more
optional handles or straps (e.g. 210, 212, 218). In this regard, the outer
shell 501 can also
include multiple reinforcement areas or patches 220 that are configured to
assist in
structurally supporting the optional handles or straps (e.g. 210, 212, 218).
The handles or
straps (e.g. 210, 212, 218) and other attachments can be stitched using
threads 222,
however these threads 222 do not, in one example, extend through the outer
shell 501
into the insulating layer 502. Rather, the threads are sewn to the patches
220, and the
patches 220 can be RF welded to the outer shell 501 or by any other method
disclosed
herein.
[49] As shown in Fig. 5A, the first outer shell portion 501a may be attached
to the second
shell portion 501b by stitching 510. However, the first outer shell portion
501a can be
attached to the second shell portion 501b using any known method, e.g.,
polymer
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welding, stitching, or other adhesive around the entire perimeter of the
second shell
portion 501b.
[50] Additionally, in one example, the base support layer 505, which can be
formed from
EVA foam, can be secured to bottom or third shell portion 501c by lamination.
The
second shell portion 501b can be secured to the third shell portion 501c and
the base
support layer 505 by polymer welding (e.g. RF welding), stitching, or
adhesives.
[51] The insulating device 10 can include two carry handles 210 that are
connected to the
frontside 216 of the insulating device 10 and the backside 217 of the
insulating device 10.
In one particular example, a shoulder strap 218 can be attached via plastic or
metal clip to
the ring 214 attached to side handles 212 to facilitate carrying insulating
device 10 over
the shoulder. The insulating device 10 may also include side handles 212 on
each end of
the cooler. The side handles 212 provide the user with another option for
grasping and
carrying the insulating device.
[52] Carry handles 210 may also form a slot for receiving rings 214 near the
bottom of the
attachment point of the carry handles to the insulating device 10. The rings
214 can be
secured to the carry handles 210 and the attachment points 213 by stitching,
adhesive, or
polymer welding and can be used to help secure or tie down the insulating
device 10 to
another structure such as a vehicle, vessel, camping equipment, and the like
or various
objects such as keys, water bottle bottles, additional straps, bottle openers,
tools, other
personal items, and the like.
[53] Additionally, as shown in Fig. 2, webbing formed as loops 224 can be sewn
onto the
straps forming the handles 210 on the back of the insulating device 10. The
loops 224
can be used to attach items (e.g., carabineers, dry bags) to the insulating
device 10. The
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side handles 212 can also provide the user with another option for securing
the insulating
device 10 to a structure.
[54] In one example, the carry handles 210, side handles 212, shoulder strap
218 and attachment
points 213 can be constructed of nylon webbing. Other materials may include
polypropylene, neoprene, polyester, Dyneema, Kevlar, cotton fabric, leather,
plastics,
rubber, or rope. The carry handles 210 and side handles 212 can be attached to
the outer
shell by stitching, adhesive, or polymer welding.
[55] The shoulder strap 218 can be attached to the insulating device 10 at
attachment points
213. The attachment points 213 can be straps that also form a slot for
receiving rings
214. The rings 214 can provide for the attachment of the shoulder strap 218.
[56] In one example, the rings 214 can be Acetal D-rings. Rings 214 in can be
plastic, metal,
ceramic, glass, alloy, polypropylene, neoprene, polyester, Dyneema, and
Kevlar, cotton
fabric, leather, plastics, rubber, or rope. Rings 214 can include other
shapes, sizes, and
configurations other than a "D" shape. Examples include round, square,
rectangular,
triangular, or rings with multiple attachment points. Additionally, pockets or
other
storage spaces can be attached to the outside of the insulating device 10 in
addition to the
carry handles 210 and side handles 212.
[57] In one example, the closure 301 can be substantially waterproof or a
barrier to prevent
liquid contents from either entering or exiting the insulating device.
Additionally, the
closure 301 can be impervious to liquid such that insulating device 10 liquid
penetration
is prevented at any orientation of the insulating device 10. Also maintaining
the closure
301 in flat plane can assist in providing a water tight seal.
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[58] Figs. 3A-3C depicts top views of the insulating device 10, and depicts
the top outer layer
or the first outer shell portion 501a and the closure 301. The top outer layer
501a
depicted in Fig. 3A can be secured to the closure 301. In one example, the
closure 301
can be a waterproof zipper assembly and can be watertight up to 7 psi above
atmospheric
pressure during testing with compressed air. However, in other examples, the
water
tightness of the closure 301 can be from 5 psi to 9 psi above atmospheric
pressure and in
other examples, the water tightness of the closure 301 can be from 2 psi to 14
psi above
atmospheric pressure. The waterproof zipper assembly can include a slider body
303 and
pull-tab 302. Fig. 3B shows a magnified view of the closure 301 that includes
bottom
stop 304 and teeth or a chain 305. In one particular example, the waterproof
zipper
assembly can be constructed with plastic or other non-metallic teeth 305 to
prevent injury
when retrieving food or beverages from the inner chamber 504.
[59] As shown in Fig. 3C, the closure 301 is open or unzipped and an aperture
512 formed in the
outer shell 501 and the inner liner 500 is open and reveals the inner liner
500 and the inner
chamber 504. It is contemplated that the closure or seal 301 can include
various sealing
devices in addition to the depicted waterproof zipper assembly in Figs. 3A-3C.
For
example, Velcro, snaps, buckles, zippers, excess material that is folded
multiple times
to form a seal such as a roll-down seal, seals, metal or plastic clamps and
combinations
thereof could be used to seal the inner liner 500 and the outer shell 501.
[60] Figs. 8A and 8B depict another exemplary insulating device 1010, which
has similar
features and functions as the example discussed above in relation to Figs. 1A-
5B in
which like reference numerals refer to the same or similar elements. However,
in this
example, a loop patch 1015 can be provided on the front of the bag. The loop
patch 1015
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can be configured to receive many types of items or a corresponding group of
hooks,
which can be placed onto the surface anywhere on various items, such as
fishing lures,
keys, bottle openers, card holders, tools, other personal items, and the like.
The loop
patch 1015 can include a logo, company name, personalization, or other
customization.
The loop patch 1015 can be formed of by needle loops and can have a high cycle
life of
over 10,000 closures. In addition, the loop patch can be washable and UV
resistant to
prevent discoloration. The loop patch can be selected based on a desired sheer
and peel
strength depending on the types of materials that are to be secured to the
insulating
device 1010.
[61] In the example shown in Figs. 8A and 8B, additionally, a strip 1013 of
material can be
provided along the bottom of the bag, which can provide additional strength
and
reinforcement to the outer shell 1501, and may enhance the aesthesis of the
insulating
device 1010.
[62] Example methods of forming the insulating device 10 will now be
described. A general
overview of an exemplary assembly process of the insulating device 10 is
depicted
schematically in FIG. 6. The various steps, however, need not necessarily be
performed
in the order described. As shown in step 602 first the portions used to form
the inner
liner 500, the outer shell 501, and the insulating layer 502 can be formed or
cut to size. In
step 604, a top cap assembly 300 can be assembled to the closure 301. In step
606, the
inner liner 500 can be formed, and in step 608, the top cap assembly 300 can
be welded
to the inner liner 500. In step 610, the outer shell 501 can be formed. In
step 612, the
insulation layer 502 can be assembled, and in step 616, the insulation layer
502 can be
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placed into the inner liner. Finally, in step 618, the top cap assembly 300
can be secured
to the outer shell 501.
[63] Referring to step 602, as shown in Fig. 7A and 7B, inner liner top
portions or first inner
liner portions 500a and top outer layer 501a that form the top cap assembly
300 can be
formed or cut to size. Fig. 7C shows a second portion or base portion 502b of
the
insulating layer 502 being cut or formed to size from stock foam. In this
example, the
base portion 502b is cut from the stock foam 530, by cutting tool 700. In one
example,
the cutting tool 700 can be formed in the shape of the base portion 502b.
[64] Referring now to step 604 and Fig. 7D, the top outer layer 501a and the
top inner liner
portion 500a can be secured to the closure 301 to form the top cap assembly
300, and the
top outer layer 501a and the top inner liner portion 500a can be secured to
the closure 301
in a flat, horizontal plane. Referring to Figs. 5A-5B the top outer layer 501a
can be
attached by polymer welding or adhesive to closure 301. In particular as shown
schematically in Fig. 5B, the closure 301 can be provided with a first flange
301a and a
second flange 301b, which can form waterproof zipper tape 306. The top outer
layer
501a can be attached directly to the top surfaces of the first flange 301a and
the second
flange 301b of the closure 301. In one example, the first flange 301a and the
second
flange 301b, can be RF welded to the underside of the top outer layer 501a. In
another
example, as shown in Fig. 7E, the top inner liner portion 500a can be provided
with tabs
515. Tabs 515 can assist in the assembly process to keep the outer strips of
the top inner
liner portion 500a in place during assembly and can be removed after the top
cap
assembly 300 is formed.
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[65] In one example, the top inner liner portion 500a can be attached to the
structure of the
insulating device 10 as shown schematically in Fig. 5B. In particular, the top
inner liner
portion 500a can be attached to the bottom of the closure 301. For example, as
shown in
Fig. 5B, and a first end 540a and a second end 540b of the top inner liner
portion 500a
can be attached to undersides of the first flange 301a and the second flange
301b. The
top inner liner portion 500a and the top outer layer 501a can be attached to
the closure
301 by polymer welding or adhesive. Polymer welding includes both external and
internal methods. External or thermal methods can include hot gas welding, hot
wedge
welding, hot plate welding, infrared welding and laser welding. Internal
methods may
include mechanical and electromagnetical welds. Mechanical methods may include
spine
welding, stir welding, vibration welding, and ultrasonic welding.
Electromagnetical
methods may include resistance, implant, electrofusion welding, induction
welding,
dielectric welding, RF (Radio Frequency) welding, and microwave welding. The
welding
can be conducted in a flat or horizontal plane to maximize the effectiveness
of the polymer
welding to the construction materials. As a result, a rugged watertight seam
can be created
that prevents water or fluids from escaping from or into the inner chamber
504.
[66] In a particular example, the polymer welding technique to connect the top
inner liner
portion 500a to the bottom of the closure 301 can include RF welding. The RF
welding
technique provides a waterproof seam that prevents water or any other fluid
from
penetrating the seam at pressure up to 7 psi above atmospheric pressure. The
insulating
device 10, therefore, can be inverted or submerged in water and leakage is
prevented both
into and out of the internal chamber 504 formed by inner liner 500. In one
example, the
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insulating device 10 can be submerged under water to a depth of about 16 feet
before
water leakage occurs. However, it is contemplated that this depth could range
from about
11 feet to 21 feet or 5 feet to 32 feet before any leakage occurs.
[67] Next referring to step 606 and Fig. 7F, the inner layer mid-portion 500b
can be formed by RF
welding. As shown in Fig. 7F, the inner layer mid-portion 500b can be formed
of a
rectangular sheet of material. The inner layer mid-portion 500b can also be
secured to
the inner layer bottom portion 500c in a subsequent step not shown.
[68] Referring to step 608 and Figs. 7G and 7H, the inner layer mid portion
500b and the inner
layer bottom portion 500c can be secured to the top cap assembly 300 using an
RF
welding operation.
[69] Referring to step 610, the second shell portion 501b and the third shell
portion 501c,
which supports the base support layer 505, can be RF welded to construct the
outer shell
501 for the insulating device 10. In one example, as shown schematically in
Fig. 5A, the
top outer layer 501a can be sewed to the perimeter of the second shell portion
501b to
form the outer shell 501 of the insulating device. A fabric binding can be
used to cover
the stitched seam edges of the second shell portion 501b and the top outer
layer 501a.
This assists in closing or joining the outer shell 501 around the insulating
layer 502.
[70] Referring to step 612 and Fig. 71, the insulating layer 502 can be
constructed. In one
example the first portion 502a of the insulating layer 502 can be formed into
a rectangular
shape and can be secured at the smaller sides of the rectangular shape using
double sided
tape to form the cylindrical shape. The second portion or base portion 502b
can be formed
into an oval shape that can have a smaller circumference than the
circumference of the
cylindrical shape of the first portion 502a. The second portion 502b
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can be secured to the first portion 502a also using a double-sided tape to
form the
insulating layer 502. In one example, double sided tape can be placed either
around the
inner perimeter of the first portion 502a cylinder or around the outer
perimeter of the base
portion 502b, and the base portion 502b can be adhered to the first portion
502a. Other
methods of securing the base portion 502b to the first portion 502a to form
the insulating
layer 502 are contemplated, such adhesives or polymer welding.
[71] Referring to step 614, the assembled insulating layer 502 can be placed
into the outer
shell 501. In step 616, the formed inner liner 500 and top cap assembly 300
can be
placed into the insulating layer 502.
[72] Finally in step 618 the top cap assembly 300 can be sewed to the outer
shell 501 to form
seams 520 as depicted schematically in Fig. 5A. In this way, neither the inner
liner 500
nor the outer shell 501 need to be bound to the insulating layer 502. Also the
inner liner
500 is only connected to the closure 301 and the closure 301 holds the inner
liner and the
outer shell 501 together, which results in a simpler manufacturing process.
After sewing
the top cap assembly 300 to the outer shell 501, a fabric binding is added to
cover the raw
edges adjacent the seams 520. Thus, the top seams 520 can be the only primary
seams on
the insulating device 10 that are created by stitching.
[73] In one particular example, the inner liner 500 and the outer shell 501
can be constructed
from double laminated TPU nylon fabric. Nylon fabric can be used as a base
material for
the inner liner 500 and the outer shell 501 and can be coated with a TPU
laminate on each
side of the fabric. The TPU nylon fabric used in one particular example is 0.6
millimeters
thick, is waterproof, and has an antimicrobial additive that meets all Food
and Drug
Administration requirements. In one specific example, the nylon can be 840d
nylon
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with TPU. Alternative materials used to manufacture the inner shell or chamber
504 and
outer shell 501 include PVC, TPU coated nylon, coated fabrics, and other
weldable and
waterproof fabrics.
[74] A closed cell foam can be used to form the insulating layer 502 that is
situated in between the
inner liner 500 and the outer shell 501. In one example, the insulating layer
502 is 1.0
inches thick. In one example, the insulating layer 502 can be formed of
NBR/PVC blend
or any other suitable blend. The thermal conductivity of an example insulating
layer 502
can be in the range of 0.16¨ 0.32 BTU.in/(hr- sqft. F), and the density of the
insulating
layer 502 can be in the range of 0.9 to 5 lbs/ft3. In one example, the thermal
conductivity
of the insulating layer 502 can be in the range of 0.25 BTU.in/(hr sqft. F),
and the
density of the insulating layer 502 can be 3.5 lbs/ft3.
[75] The foam base can be manufactured from an NBR/PVC blend or any other
suitable
blend. In addition to the base portion 502b of the insulating layer 502, the
insulating
device 10 may also include an outer base support layer 505 constructed of
foam, plastic,
metal or other material. In one example, the base portion 502b can be detached
from the
base support layer. In one example, the base portion 502b is 1.5 inches thick.
Additionally as shown in Fig. 5A, the EVA foam base support layer 505 can be
0.2
inches thick. Although the base support layer 505 is laminated to the base
outer layer or
third shell portion 501c, in an alternative example, the base support layer
505 can be
attached to the bottom of the base portion 502b by co-molding, polymer
welding, adhesive,
or any known methods.
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[76] A heat gain test was conducted on the exemplary insulating device 10. The
purpose of a heat
gain test is to determine how long the insulating device can keep temperature
below 50 F
at an ambient of 106 F 4 with the amount of ice based on its internal
capacity.
[77] The procedure is as follows:
[78] 1. Turn on the oven and set to 106 F 4. Allow the oven to stabilize for
at least one hour.
[79] 2. Turn on the chart recorder. The recorder shall have three J-
thermocouples connected
to it to chart the following temperatures: (1) Test unit, (2) Oven, and (3)
Room ambient.
[80] 3. Stabilize the test unit by filling it to half its capacity with ice
water, and allowing it to
sit for 5 minutes at room temperature (72 F 2).
[81] 4. After 5 minutes, pour out the contents, and immediately connect the J-
thermocouple end
to the inside bottom center of the unit The thermocouple wire end must be
flush to the
inside bottom surface and secured with an adhesive masking tape.
[82] 5. Pour the correct amount of ice ensuring the thermocouple wire is not
moved. Amount
of ice is based on 4 lbs. per cubic feet of the internal capacity of the unit.
[83] 6. Close the lid and position the test unit inside the oven.
[84] 7. Close the oven making sure the thermocouple wires are functioning.
[85] 8. Mark the start of the chart recorder.
[86] Apparatus: 1. Oven. 2. Ice. 3. Chart Recorder. 4. J-Thermocouples (3).
Results: 1. Cold
Retention Time: Elapsed time from <32 F to 50 F in decimal hours. 2. Heat Gain
Rate
( F/Hr): (50 F ¨ 32 F) Elapsed Time = 18 F Elapsed Time
[87] In one test of the example insulating device, the heat gain rate equaled
1.4 degF/hr
assuming 26.5 quarts capacity and used 3.5421bs of ice for the test.
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[88] The ability of the insulating device 10 to withstand interior leaks can
also be tested to see how
well the insulating device maintains the contents stored in the storage
compartment or
receptacle 504. In one example test, the insulating device 10 can be filled
with a liquid,
such as water, and then can be inverted for a predetermined time period to
test for any
moisture leaks. In this example, the insulating device 10 is filled with a
liquid until
approximately half of a volume of the receptacle 504 is filled, e.g. 3 gallons
of water, and
the closure 301 is then closed fully to ensure that the slider body 303 is
completely sealed
into the horseshoe-shaped portion 308. The entire insulating device 10 is then
inverted
and held inverted for a time period of 30 minutes. The insulating device 10 is
then
reviewed for any leaks.
[89] The insulating device 10 can be configured to withstand being held
inverted for 30
minutes without any water escaping or leaving the receptacle 504. In
alternative examples,
the insulating device can be configured to withstand being held inverted for
15 minutes to
120 minutes without any water escaping or leaving the receptacle 504. To
perform this
test, it may be helpful to lubricate the closure to ensure that the closure is
adequately
sealed. For example, as shown in Fig. 9, a horseshoe-shaped portion 308 of the
closure
301 is provided with lubricant 309.
[90] The strength and durability of the fabric forming the outer shell 501,
inner liner 500 and the
insulating layer 502 of the insulating device 10 may also be tested. In one
example, the
test can be devised as a puncture test. In particular, this test can be
designed as an ASTM
D751-06 Sec. 22-25 screwdriver puncture test. In one example, the insulating
device 10
can withstand 35 lbs to 100 lbs of puncture force.
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[91] The handle strength and durability of the insulating device 10 can also
be tested. One such
example test is depicted in Fig. 10. As depicted in Fig. 10, the closure 310
can be fully
closed, one of the carry handles 210 can hooked to an overhead crane 600, and
the
opposite carry handle 210 is hooked to a platform 650, which can hold weight.
In one
example, the platform 650 can be configured to hold 200 lbs. of weight. During
the test,
the crane 600 is slowly raised, which suspends the insulating device 10 in a
position
where the bottom plane of the insulating device 10 is perpendicular with the
floor. In one
example, the insulating device 10 can be configured to hold 200 lbs. of weight
for a
minimum of 3 minutes without showing any signs of failure. In alternative
examples, the
insulating device can be configured to hold 100 lbs. to 300 lbs. of weight for
I to 10
minutes without showing signs of failure.
[92] Figs. 11-15 show another example insulating device 2010. The example
insulating
device 2010 can be of a similar construction to the above examples, where like
reference
numerals represent like features having similar functionality. However, the
example
insulating device 2010 can also include a fold-down flap or portion 2307 to
assist in
insulating the closure 2311 of the insulating device 2010. Specifically, the
closure 2311,
which can be a zipper in accordance with the other examples discussed herein,
can be
included on a fold-down flap or portion 2307 and can be front facing in that
it is located
on a front surface or wall of the insulating device 2010. The front facing
closure 2311,
can allow for additional user access to the insulating device 2010, and the
fold-down flap
or portion 2307 can help to provide additional insulation at the closure 2311.
In this
example, when the fold-down flap 2307 is in the extended position and the
closure 2311
is open or unsealed, the contents in the insulating device 2010 maintain the
closure 2311
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in the open position for better access of the contents of the insulating
device 2010. This
may assist the user to be able to more easily access the contents of the
insulating device
2010. Also as shown in Fig. 11, when the fold-down flap 2307 is in the
extended
position, the insulating device 2010 can approximate a trapezoidal shape for
providing an
elongated closure at the top of the insulating device 2010.
[93] As shown in the side and cross-sectional views, i.e., Figs. 12 and 14A,
the insulating
device 2010 can approximate a pentagon, when the fold-down flap 2307 of the
insulating
device 2010 is in an extended position. This general shape may provide for an
insulating
device 2010 that may be easily shipped in that several insulating devices can
be fit into a
shipping container. Nevertheless, other shapes and configurations are
contemplated e.g.,
square, rectangular, triangular, conical, curved, and frusto-shapes which may
provide an
extended closure at the top of the insulating device 2010 and that can be
easily packaged.
[94] Like in the above examples, the insulating device 2010 may include an
outer shell 2501,
an inner liner 2500 forming a storage compartment, a receptacle, or inner
chamber 2504
and an insulating layer 2502 positioned in between the outer shell 2501 and
the inner
liner 2500. The insulating layer 2502 provides insulation for the storage
compartment
2504. The closure 2311 can be configured to substantially seal an opening
2512, which
is located on an angled front facing surface and extends through the outer
shell 2501 and
the inner liner 2500 to provide access to the storage compartment 2504. Also,
the closure
2311 can include similar features and functionality in accordance with the
examples
discussed above. In one example, the closure 2311 can be a zipper and can be
substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device
2010 is in any orientation. Also, similar to the above examples, the
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insulating device 2010 can be provided with one or more of carry handles 2210,
shoulder
straps 2218, webbing loops 2224 formed with threads 2222 by stitching for
example,
rings 2214, and attachment points 2213 which can have similar features and
functionality
as in the examples above.
[95] As shown in Figs. 11 and 12 and as noted above, the fold-down flap 2307
may include the
front facing closure 2311 and can be folded over and secured to a sidewall of
the
insulating device 2010 to further insulate the front facing closure 2311. The
fold-down
flap 2307 of the fastening mechanism 2301 can include first and second end
hooks or
clips 2313a, 2313b. In one example, each of the end clips 2313a, 2313b can
include a
slot 2317a, 2317b for being received in corresponding loops 2315a, 2315b
located on the
sides or the sidewalls of the insulating device 2010. To close the insulating
device 2010,
the fold-down flap 2307 along with the front facing closure 2311 are folded
over onto a
front face or wall of the insulating device 2010. The fold-down flap 2307
folds over with
and conceals or covers the front facing closure 2311. The fold-down flap 2307
is held
into place by the first and second end clips 2313a, 2313b and maintains the
fastening
mechanism 2301 in the closed position. Additionally, when the fold-down
portion 2307
is secured to the sidewalls of the insulating device 2010, the fold-down
portion 2307
extends at least partly in a substantially horizontal direction, which orients
a carrying
handle 2318 in position for a user to grasp for holding and carrying the
insulating device
2010. As in the other handles and straps, the carry handle 2318 can be secured
to the
outer shell with a reinforcement patch (not shown). The carry handle 2318 can
be
provided on the rear surface of the insulating device 2010 to oppose the
closure 2311 on
the front facing surface, which can be used by the user to grasp during
opening and
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closing the insulating device 2010 to make it easier for the user to open and
close the
closure 2311. The carry handle 2318 may also be used for hanging the
insulating device
2010, or for carrying the insulating device 2010; however, other uses are also
contemplated.
[96] Fig. 14A shows a cross-sectional side view of the insulating device 2010.
The insulating
device 2010 includes an inner liner 2500, an insulating layer 2502, and an
outer shell
2501. As shown in Fig. 14A, like in the above examples, the insulating layer
2502 can be
located between the inner liner 2500 and the outer shell 2501, and can be
formed as a
foam insulator to assist in maintaining the internal temperature of the
receptacle 2504 for
storing contents desired to be kept cool or warm. Also the insulating layer
2502 can be
located in between the inner liner 2500 and the outer shell 2501, and can be
unattached to
either the inner liner 2500 or the outer shell 2501 such that it floats
between the inner
liner 2500 and the outer shell 2501. In one example, the inner liner 2500 and
the outer
shell 2501 can be connected at the top portion of the insulating device 2010
such that the
insulating layer 2502 can float freely within a pocket formed by the inner
liner 2500 and
the outer shell 2501.
[97] In this example, the inner layer or inner liner 2500 can be formed of a
first inner liner
sidewall portion 2500a and a bottom inner liner portion 2500b. The first inner
liner
sidewall portion 2500a and the bottom inner liner portion 2500b can be secured
together,
by for example welding, to form the chamber 2504. Like in the above example,
the
chamber 2504 can be a "dry bag," or vessel for storing contents. In one
example, a tape,
such as a TPU tape, can be placed over the seams joining the sections of the
chamber
2504, after the first inner liner sidewall portion 2500a and the bottom inner
liner portion
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2500b are secured or joined together. The tape seals the seams formed between
the first
inner liner sidewall portion 2500a and the bottom inner liner portion 2500b to
provide an
additional barrier to liquid to prevent liquid from either entering or exiting
the chamber
2504. The inner liner 2500 can, thus, either maintain liquid in the chamber
2504 of the
insulating device 2010 or prevent liquid contents from entering into the
chamber 2504 of
the insulating device 2010. It is also contemplated, however, that the inner
liner 2504 can
be formed as an integral one-piece structure that may be secured within the
outer shell.
[98] As shown in both Figs. 14A and 15, the insulating layer 2502 can be
formed of a first
portion or an upper portion 2502a, a second portion or base portion 2502b, and
a base
support layer 2505. In addition, the first portion 2502a can include a top
flap or smaller
rectangular shape 2502a 1 . When the fold-down flap 2307 is folded onto the
top portion
of the insulating device 2010, the top flap 2502a1 of the insulating layer
together with the
remainder of the first portion 2502a and the base portion 2502b surrounds
substantially
all of the inner chamber 2504 with insulation to provide a maximum amount of
insulation
to the inner chamber 2504 of the insulating device 2010.
[99] When the upper portion 2502a is rolled flat, the upper portion 2502a of
the insulating
layer 2502 generally resembles a "T" shape such that the insulating layer
defines a first
height Hi and a second height H2 where the first height Hi is greater than the
second
height H2. In this example, a majority of the insulating layer can extend to
the second
height H2, which is less than the first height Hi. Also, the first portion
2502a can be
formed of two inter-connected rectangular shapes, where the bottom of the
first portion
2502a forms a first larger rectangular shape 2502a2 and an upper section of
the first
portion 2502a forms the top flap 2502a1 of the smaller rectangular shape. It
is also
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contemplated that the first larger rectangular shape 2502a2 can be formed as a
separate
piece from the smaller rectangular shape 2502a 1 . The first rectangular shape
2502a2 can
have a first rectangular width and the second rectangular shape 2502a1 can
have a second
rectangle perimeter and first rectangular shape 2502a2 width approximates the
second
rectangular shape 2502a1 perimeter. In one example, the smaller rectangular
shape
2502a1 forms a top flap of the insulation layer of the upper portion 2502a,
which extends
into the fold-down portion 2307.
[100] The first portion 2502a and the second portion 2502b can be formed of an
insulating
foam material as discussed herein. In one example, the second portion 2502b
can be
formed of a thicker foam material than the first portion 2502a. For example,
the thickness
of the second portion 2502b can be formed between 20 mm and 50 mm thick, and,
in one
particular example, can be formed of a 38 mm thick foam, and the first portion
2502a
can be formed between 15 mm and 30 mm, and, in one particular example, can be
formed
of a 25 mm thick foam. In one example, the foam can be a NBR/PVC blended foam,
a
PVC free NBR foam, or other eco-friendly type foam.
[101] Also as shown in Fig. 15, a base support layer 2505 adds to the
insulation and the
structural integrity of the insulating device 2010 at base 2215. The base
support layer
2505 may also provide additional protection around the bottom of the
insulating device
2010. In one example, the base support layer 2505 can be formed from EVA foam.
The
base support layer 2505 may include a certain design such as a logo or name
that can be
molded or embossed directly into the material. A base support ridge 2400,
which
provides structural integrity and support to the insulating device 2010 can
also be molded
or embossed directly into the base support layer 2505. In one example, the
base support
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layer 2505 and the base portion 2502b can be detached or unsecured for ease of
assembly
in reducing the number of assembly steps. The base portion 2502b can be formed
as an
oval shape to close off a lower opening 2506 formed by the open shape of the
upper
portion 2502a.
[102] The bottom of the first portion 2502a maintains its form when folded
into an oval-
cylindrical shape and placed in between the inner liner 2500 and the outer
shell 2501.
The insulating layer 2502 maintains its shape which results in the basic oval-
cylindrical
shape of the insulating device 2010.
[103] The outer shell 2501 can be formed of an upper sidewall portion 2501a, a
lower sidewall
portion 2501b, and a base portion 2501c. Each of the upper sidewall portion
2501a, the
lower sidewall portion 2501b, and the base portion 2501c can be secured by
stitching.
Other securing methods are also contemplated, such as, using welds or
adhesives.
[104] Additionally, the fold-down portion 2307 can be at least partly free of
foam to make it
easier to close the fastening mechanism 2301. In particular, the fold-down
portion 2307
can include a first section 2307a and a second section 2307b. The first
section 2307a can
be free of the insulation layer 2502 and the second section can include the
insulation
layer 2502.
[105] Referring to Fig. 14B, like in the above examples, the closure 2311 can
be mounted on a
backing or fabric. In the case of a zipper this can be referred to as zipper
tape 2306.
Also, like in the above examples, the zipper tape 2306 can be attached between
the inner
liner 2500 and the outer shell 2501 and, in particular, the zipper tape 2306
can be secured
to the upper sidewall portion 2501a of the outer shell and the first inner
liner sidewall
portion 2500a. As shown in Fig. 14B, the zipper tape 2306, the upper sidewall
portion
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2501a of the outer shell, and the first inner liner sidewall portion 2500a can
form a
stacked arrangement of a sandwich structure where the zipper tape 2306 is
located
between the upper sidewall portion 2501a of the outer shell and the first
inner liner
sidewall portion 2500a.
[106] The insulating device 2010 can be formed using similar techniques in
relation to the
examples as discussed above. For example, the upper sidewall portion 2501a of
the outer
shell 2501 can be formed. Also the base 2215 can be formed separately with the
base
portion 2502b of the insulation layer 2502, the base support layer 2505, the
lower
sidewall portion 2501b, and a base portion 2501c of the outer shell 2501
according to the
techniques discussed herein. The base 2215 can be secured to the bottom of the
upper
sidewall portion 2501a of the outer shell 2501 using the techniques discussed
herein. The
upper portion 2502a of the insulation layer 2502 can be placed within the
upper sidewall
portion 2501a of the outer shell 2501. The first inner liner sidewall portion
2500a and the
bottom inner liner portion 2500b can then be secured to form the inner liner
2500 and
chamber 2504. Tape, such as a TPU tape, can be placed over the seams joining
the
sections of the inner liner 2500 and chamber 2504. The inner liner 2500 can
then be
placed within the insulation layer 2502. The closure 2311 can then be attached
between
the inner liner sidewall portion 2500a and the upper sidewall portion 2501a.
At this point
in the process the insulating device 2010 assembly will have a cylindrical
shape with an
open top. To close the open top, the upper ends of the inner liner sidewall
portion 2500a
and the upper sidewall portion 2501a can then be secured together by welding
or by using
any of the techniques discussed herein to form the insulating device 2010. A
binding
2518 can be applied to the top portion of the insulating device 2010 to cover
and conceal
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the seam between the outer shell 2501 and the inner liner 2500. The loop patch
(not
shown), carry handles 2210, shoulder strap 2218, webbing loops 2224, and rings
2214
can be added to the outer shell 2501 by the various techniques discussed
herein, after the
formation of the outer shell or once the insulating device 2010 is formed. It
is
contemplated that the inner liner and the outer liner can be formed by
welding, gluing, or
stitching and combinations thereof.
[107] In another example, a magnetic connection can be implemented for
securing the fold-
down portion 2307 to the body of the insulating device 2010. As shown in Figs.
16A and
16B, the insulating device 2010 can be provided with a magnetic clip 3313,
which can be
received by a corresponding magnet (not shown) on the sidewall of the
insulating device
2010. However, it is also contemplated that the clip and clip receiving
portion on the
insulating device 2010 could be one or more of permanent magnets, metal
strips, or
ferromagnetic materials. In addition, other methods of securing the fold-down
flap 2307
over the front facing closure 2311 are also contemplated. For example, one or
more of
hook and loop, buckle, snap, zipper, detent, spring loaded detent, button,
cams, or threads
could be used to secure the fold-down flap 2307 to the sidewall of the
insulating device
2010.
[108] Figs. 17-22 show another exemplary insulating device 4010. The example
insulating
device 4010 can be of a similar construction to the above examples and, in
particular, the
example discussed above in relation to Figs. 11-16B, where like reference
numerals
represent like features having the same or similar functionality. In this
example, the
insulating device 4010 does not include a fold-down flap and can include a
different
overall shape than the example insulating device 2010. Additionally, the
insulating layer
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4502 can have a different configuration along with other variations that will
be discussed
below. Like in the above example, the closure 4311 can be placed on a front
face or wall
of the insulating device 4010.
[109] As shown in Figs. 18 and 19, when viewed from the front and rear, the
insulating device
4010 can generally form a trapezoidal shape, where the insulating device
diverges or
tapers upward toward the top of the insulating device 4010. The trapezoidal
shape may
provide certain insulation, user accessibility, and packaging benefits. For
example, the
trapezoidal shape can provide an extended period of ice coverage because of
the
additional foam that can be placed between the outer shell 4501 and the inner
liner 4500
due to the trapezoidal shape.
[HO] Additionally, the overall shape of the insulating device 4010 can help to
maintain the
insulating device 4010 in the opened position when the closure 4311 is in the
opened
position and permits the user to be able to easily access the contents of the
insulating
device 4010. The trapezoidal shape as discussed herein also allows the closure
4311 to
be formed longer relative to the insulating device 4010. Other shapes that
allow for an
extended opening at the upper portion of the insulating device 4010 are also
contemplated. For example, the upper portion of the insulating device 4010
could be
formed with an extended curvature either upward or downward to allow for a
larger
closure extending across the upper portion of the insulating device 4010. Also
as shown
in Fig. 20, when viewed from the side, the insulating device 4010 can be
formed generally
conical, tapered or funnel-shaped such that the sides converge to the top of
the insulating
device 4010. Also the sides can be formed substantially parabolic in shape in
certain
examples. Therefore, the insulating device 4010 converges to an apex along the
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top of the insulating device 4010 as opposed to an oval shape with the same
perimeter as
the bottom of the insulating device 4010.
[111] In certain examples, a trapezoidal shape may also provide for an
insulating device 4010
that may be easily shipped in that several insulating devices 4010 can be fit
into a
shipping container. For example, multiple insulating devices 4010 could be
arranged in a
shipping container in different orientations so as to utilize more space
within a shipping
container.
[112] In alternative embodiments, when the closure 4311 is in the opened or
unsealed position,
the contents in the insulating device 4010 may maintain the closure 4311 in
the open
position for easier access to the contents of the insulating device 4010. In
this example,
the weight of the contents can force a lower half of the closure 4311 away
from an upper
half of the closure 4311 such that the user can better see the contents of the
insulating
device 4010 and more easily remove the contents or add contents to the
insulating device
4010.
[113] In this example, the outer shell construction, insulating layer, and the
inner liner
construction can be similar to that of the embodiment discussed above in
relation to Figs.
11-16B, the details of which are not repeated here. The outer shell 4010 may
also include
a top portion 4316, which is configured to receive the closure 4311 therein.
The top
portion 4316 can be formed of the same material as the remaining outer shell
4501, which
in one specific example, can be nylon and specifically an 840d nylon with TPU.
[114] Similar to the example discussed in relation to Figs. 11-16B, the
insulating device 4010
can be provided with one or more of carry handles 4210, a shoulder strap 4218,
webbing
loops 4224, which are formed by threads 4222, rings 4214, and attachment
points 4213
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which can have similar features and functionality as in the examples above.
Additionally,
a rear carry handle 4318 can be provided on the rear surface of the insulating
device 4010
to oppose the closure 4311, which can be used by the user to grasp during
opening and
closing the insulating device 4010 to make it easier for the user to open and
close the
closure 4311. The rear carry handle 4318 may also be used for hanging the
insulating
device 4010 for drying the inner chamber 4504, or for carrying the insulating
device 4010.
Each of the carry handles 4210, shoulder strap 4218, webbing loops 4224, and
attachment
points 4213 can be reinforced by one or more of additional structures in the
form of
webbing or suitable polymeric materials. This reinforcement material may be
applied to
any of the examples discussed herein.
[115] Also as shown in Figs. 17 and 21 a binding 4518 can be included that
extends over the
top of the insulating device 4010 to secure the outer shell 4501 to the inner
liner 4500.
The binding 4518 can be folded over the top of the insulating device 4010 and
then
stitched over the over outer shell 4501 and the inner liner 4500 to form a
cover to the
joint or seam between the inner liner 4500 and the outer shell 4501. As shown
in Fig. 18,
the binding 4518 can be folded into thirds to form a first folded portion
4518a where the
first third is attached to a first side of the insulating device 4010, the
second third is
extends over the top of the insulating device 4010, and the last third is
attached to a
second side of the insulating device 4010. The binding 4518 covers the seam
between
the outer shell 4501 and the inner liner 4500 along the top of the insulating
device 4010.
Also, as shown in Fig. 17, the binding 4518 extends from the top of the
insulating device
4010 and forms a second folded portion 4518b where the binding 4518 is folded
in half
and a third unfolded portion 4518c, which forms and extends to attachment
points 4213
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that receive rings 4214. Each side of the insulating device 4010 can include a
second
folded portion 4518b and a third unfolded portion 4518c such that the
insulating device
4010 can include two second folded portions 4518b and two third unfolded
portions
4518c. The binding 4518 can unfold closer to the attachment points 4213 and
may also
be formed unfolded from the attachment points 4213 to the top of the insulated
device
4010. In either of these configurations, a section of the binding 4518, e.g.,
the second
folded portion 4518b, can be unattached to the insulating device 4010 and
folins a strap
between the folded portion 4518a and the attachment points 4213. In this
example, two
straps can be formed by the two second unfolded portions 4518b and can be
grasped by
the user for handling the insulating device, can be used for hanging the
insulating device
4010 for drying, and the like. Also, the attachment points 4213 formed by the
binding
4518 can be a loop or slot for receiving the rings 4214.
[116] Figs. 22 and 22A show the insulating layer 4502 in additional detail,
which is similar to
the example insulating device 4010 discussed above where like reference
numerals
represent like components with the same or similar functionality. The
insulating layer
4502 can be formed of the materials as discussed herein and, in certain
examples, can be
PVC free and/or can have non-thermoset properties such that the foam is fully
resilient.
Like the above examples, the upper portion 4502a of the insulating layer 4502
can be
formed of a single sheet of material which is rolled into the shape defined by
the opening
between the inner liner 4500 and the outer shell 4501. As shown in Fig. 22,
the
insulating layer 4502, like in the above examples, can be formed of a first
portion or an
upper portion 4502a and a second portion or base portion 4502b. The rear top
flap
4502a1 can be formed in smaller rectangular shape. The rear top flap 4502a1
extends
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higher than the front side of the first portion 4502a of the insulating layer
4502a to
accommodate for the front facing closure 4311. Specifically, the rear top flap
4502a1 can
extend to a first height H3, and the first portion 4502a can extend to a
second height H4,
and the first height 1-13 can be greater than the second height H4.
Additionally, as shown
in Fig. 22, a majority of the insulating layer 4502 can extend to the second
height H4.
Alternatively, as shown in Fig. 22A, the rear half of the insulating layer
4502 can extend
to the first height H3 and the front half of the insulating layer 4502 can
extend to the
second height H4. Additionally, as shown in Fig. 22A, the insulating layer
4502 can taper
from die first height H3 to the second height H4. Also, this provides the
areas of the
insulating layer 4502 near the top with tapered or chamfered portions along
the sides of
the insulating device 4010 to provide a smaller profile on each side of the
insulating
device 4010.
[117] In one example, the first portion 4502a can define a first area Ai, and
the rear top flap
4502a1 can define a second area A2, which is smaller than the first area Ai.
When
installed between the inner liner 4500 and the outer shell 4501, the
insulating layer 4502
generally follows the conical and trapezoidal shape of the profile of the
insulating device
4010. Additionally, the upward tapered profile of the outer shell 4501 and the
inner liner
4500 can help to position the insulating layer 4502 such that the insulating
layer covers a
majority of the inner liner 4500.
[118] In particular, as shown in Fig. 21, the insulating layer 4502 occupies a
majority of the
space formed between the inner liner 4500 and the outer shell 4501. The
insulating layer
4502 extends substantially to the top of the insulating device 4010 in both
the front and
the rear portions of the insulating device 4010 to insulate a majority of the
compartment
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4504. As a result, the insulating layer 4502 surrounds substantially the
entire inner
chamber 4502 to provide a maximum amount of insulation to the inner chamber
4504 of
the insulating device 2010. In one example, the insulating layer 4502 covers
80% or
more of the inner liner 4500 covering the inner chamber 4504, and in
particular examples
the insulating layer 4502 covers 85%, 90%, or 95% or more of the inner liner
4500
covering the inner chamber 4504.
[119] In the examples discussed in relation to Figs. 11-22, the front facing
closures 2311, 4311
can be formed such that they extend a majority of the way along the front
facing surface
of the insulating devices 2010, 4010. As discussed above, the front-facing
closures 2311,
4311 can be formed as zipper closures in accordance with the examples
discussed herein.
In one example, the closures 2311, 4311 can be substantially waterproof or
highly water
resistant and can be water tight and air tight. The front facing closures
2311, 4311 can be
formed as long as possible in the front facing surface of the insulating
devices 2010, 4010
to provide for extended user accessibility and visibility of the contents
stored in the
insulating devices 2010, 4010. In one example, the closures 2311, 4311 can
define a first
length Li, and the top portion of the insulating device 4010 can define a
second length L2.
[120] In one example, L2 can be 3 cm to 10 cm longer than Li, the length of
the front facing
closures 2311, 4311 and in one specific example can be 5 cm longer than the
front-facing
closures 2311, 4311. The closures 2311, 4311 first length Li can extend at
least 80% of
the second length L2 and up to 98% of the second length L2. In one particular
example,
the length of the closures 2311, 4311, Li can extend across 87% of the second
length L2.
[121] Additionally, the length Li of the front-facing closures 2311, 4311 can
be formed longer
than the length L3 of the bases of the insulating devices 2010, 4010. In
certain examples,
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the front facing closures 2311, 4311 can be formed approximately 1% to 25%
longer than
the length L3 of the bases of the insulating devices 4010. In one specific
example the
length Li of the front facing closures 2311, 4311 can be 10% longer than the
length L3 of
the bases. For example, the front-facing closures length Li can be formed 3 cm
to 12 cm
longer than the length L3 of the bases of the insulating devices, and, in one
particular
example, the length Li of the front facing closures 2311, 4311 can be 5 cm
longer than
the length L3 of the base.
[122] In still other embodiments, the insulating device can include a closure
that extends
around the entire perimeter or a majority of the perimeter of the insulating
device and a
front facing closure 2311, 4311 as discussed above. In this particular
example, the
contents of the insulating device can be easily accessed by the user once the
entire or a
majority of the top portion is removed or through the closure 2311, 4311.
[123] In another example, the insulating device can be formed modular such
that the top and/or
the bottom can be removed and multiple structures can be interconnected to
form larger
or smaller insulating devices. For example, the insulating device can be
formed of
different sections by way of removable fasteners, such as snaps, zippers,
threads, seals,
hook and loop, and the like.
[124] In relation to the examples discussed herein, a series of vents can be
provided along the
outer shells of the insulating devices. The vents allow for any gases that are
trapped
between the inner liner and the outer shell to escape. Without the vents, the
gases trapped
between the inner liner and the outer shell can cause the insulating device to
expand,
which in certain instances, may not be desired. In certain examples, the one
or more
joints or seams that connect the various portions of the outer shell provide
vents for
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gases. Vents can be provided in areas of the outer shell where the outer shell
fabric is
pierced. For example, tiny openings can be provided at any of the stitching
locations
where the various components are located on the insulating devices.
Specifically, the
vents can be provided in the areas where the handles, molle loops, straps,
reinforcement
patches, bindings, D-rings, loop patches, etc. are attached to the outer shell
of the
insulating device. For example, stitching that may be used to secure these
components to
the outer shell provides openings into the outer shell, which creates venting
between the
insulation layer and the outer shell. In one specific example, the insulating
device may
vent through binding 4518.
[125] The example insulating device 4010 was tested to determine ice
retention. As such, the
ice retention testing may be utilized to determine insulative properties of
example
insulating device 4010. In an exemplary test, the duration of the increase
from 0 F to
50 F when the insulating device 4010 was filled with ice was determined
according to
the test parameters below. In certain examples, the temperature of the
insulating device
increases from 10 F to 32 F in a duration of 24 hours to 24 hours, the
temperature of the
insulating device increases from 32 F to 50 F in a duration of 36 hours to 68
hours, and
the temperature of the insulating device increases from 0 F to 50 F in a
duration of 70
hours to 90 hours.
[126] The ice retention was tested using the following test. More than 24
hours before the test, the
following steps are performed:
= Ensure test coolers are clean inside and out.
= Mark test coolers with unique identifier and record identifier and
description in test
log or notes.
= Using duct tape, place a thermocouple (T) in the approximate center of
the test
cooler (C).
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= The thermocouple tip should be approximately 1 inch above the cooler
floor. (See
Fig. 23 for an example of proper thermocouple set-up.)
= Condition test coolers by keeping test coolers inside (ambient
temperature 65-75 F)
with lids open for a minimum of 24 hours.
= Calculate the amount of ice required for testing (to nearest 0.1 lbs.)
using the
equation below.
o Ice per cooler = 0.52 lbs. x Quart capacity of cooler
o Ice required = Ice per cooler x number of coolers
= Condition the ice by placing the ice in a freezer (-15 to -5 F) for a
minimum of 24
hours prior to use.
[127] The day of the test, the following steps are performed:
= Gather Test Equipment
= Allow thermal chamber to reach a temperature of 100 F
= Scale ¨ place scale near freezer with test ice
= Data Logger ¨ ensure Data Logger has charged battery
[128] The test procedure is as follows:
= Bring test coolers to freezer with test ice.
= Place test cooler on scale and tare the scale.
= Break test ice with hammer.
= Using the scale as reference, quickly fill the test cooler with the
required amount of
ice.
= Ensure that the ice is evenly distributed throughout the test cooler.
= Ensure that the connector end of the thermocouple is outside of the test
cooler and
close and secure the cooler lid.
= Repeat steps for the remaining test coolers.
= Arrange the coolers in the test area such that they all have even amounts
of direct
sunlight and airflow (one cooler does not block the other).
= Connect all thermocouples to the data logger.
= Check all thermocouple readings to ensure that all connections are
complete and the
channels are recording properly. (Note: The starting temperature inside each
test
cooler should be < 10 F).
= Power up the data logger and configure to record with temperatures
recorded at less
than 10 minute intervals.
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= Begin recording and note time in test log.
= Allow the test to continue until the inside temperature of each test
cooler is > 50 F.
= Stop recording.
= Disconnect thermocouples from data logger.
= Receive data from data logger.
= Remove test coolers from test area.
= Empty test coolers and allow them to dry.
= Remove thermocouples from test coolers
[129] The heat gain rate of the insulating devices 2010, 4010 can be
approximately 0.5 to 1.5
degF/hr, and, in one particular example, the heat gain rate can be
approximately 1.0
degF/hr.
[130] Like in the above examples, the ability of the insulating devices 2010
and 4010 are also
configured to withstand interior leaks and were also tested to see how well
the insulating
devices 2010, 4010 maintain the contents stored in the storage compartment or
receptacles 2504, 4504. In one example test, the insulating devices 2010, 4010
can be
filled with a liquid, such as water, and then can be inverted for a
predetermined time
period to test for any moisture leaks. In this example, the insulating devices
2010, 4010
are filled with a liquid until approximately half of a volume of the
receptacle 4504 is
filled, e.g. 3 gallons of water, and the closures 2301, 4301 are then closed
fully. The
entire insulating devices 2010, 4010 are then inverted and held inverted for a
time period
of 30 minutes. The insulating devices 2010, 4010 are then reviewed for any
leaks.
[131] The insulating devices 2010, 4010 can be configured to withstand being
held inverted for
30 minutes without any water escaping or leaving the receptacles 2504, 4504.
In
alternative examples, the insulating devices 2010, 4010 can be configured to
withstand
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being held inverted for 15 minutes to 120 minutes without any water escaping
or leaving
the receptacles 2504, 4504.
[132] An exemplary insulating device may include an outer shell, an inner
liner, an insulating
layer floating freely in between the outer shell and the inner liner, and a
waterproof
closure. The top of the shell has first perimeter circumference, and the
bottom of the
shell has a second perimeter circumference. The first perimeter circumference
can be
equal to the second perimeter circumference. The closure can be a zipper
assembly
comprising a plurality of zipper teeth, and the zipper teeth can be formed of
plastic or
metal. The outer shell can be made of a double laminated TPU nylon fabric. The
inner
liner can be made of a double laminated TPU nylon fabric. The insulating layer
can be
formed of a closed cell foam. The insulating layer can be made of a NBR and a
PVC
blend, and at least a portion of the insulating layer can be constructed with
an EVA foam
layer. The outer shell further can include at least one of a strap or handle.
The outer
shell further can include at least one ring for securing the insulating
device.
[133] An exemplary insulating device can include an outer shell, an inner
liner, a closure
adapted to seal at least one of the outer shell or the inner liner, and an
insulating layer
between the outer shell and the inner liner. The closure can have a first
flange and a
second flange, and the outer liner can be secured to top surfaces of the first
flange and the
second flange and the inner liner can be secured to bottom surfaces of the
first flange and
the second flange. The outer liner and the inner liner can be connected to the
closure by a
polymer weld. The outer shell can have a first circumference and a second
circumference, the first circumference and the second circumference both
having an oval
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shape. The closure can be adapted to be a barrier against fluid. The closure
can be a
zipper apparatus that is watertight up to 7 psi above atmospheric pressure.
[134] An exemplary method of assembling a insulating device may include
forming an inner
liner having an inner vessel, forming an outer shell, forming an insulating
layer between
the inner liner and the outer shell, and securing a closure configured to be a
barrier
against fluid penetration in and out of the inner vessel wherein the closure
is secured in a
flat plane and is secured to the outer shell and the inner shell. The outer
shell and inner
shell may only be connected to the closure and not to the insulating layer
between the
outer shell and inner liner.
[135] A waterproof polymer weld can be formed between the closure and the
inner shell and
the closure and the outer shell when the closure, the outer shell, and the
inner liner are
lying in a horizontal plane. The outer shell and the inner layer can be formed
of a TPU
nylon material. The closure can have a first flange and a second flange. The
outer liner
can be secured to top surfaces of the first flange and the second flange and
the inner liner
can be secured to bottom surfaces of the first flange and the second flange.
[136] The method can also include forming the insulating layer from a
rectangular shape, and
rolling the rectangular shape into a cylindrical shape. The top of the
insulating layer has
a first perimeter circumference and the bottom of the insulating layer has a
second
perimeter circumference. The first perimeter circumference can be equal to the
second
perimeter circumference.
[137] Another example insulating device can include an outer shell, an inner
liner forming a
storage compartment, a foam layer floating freely in between the outer and
inner liner,
the foam layer providing insulation, an opening extending through the outer
layer and the
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inner layer, and a closure adapted to substantially seal the opening. The
closure can be
substantially waterproof so as to resist liquid from exiting the opening.
[138] The insulating device can also include an upper wall and a base, the
upper wall defining an
upper wall circumference, an upper wall length and an upper wall width, and
the base
defining a base circumference, a base length and a base width. The upper wall
circumference can be equal to the base circumference and the ratio of the
upper wall
length to the upper wall width can be greater than the ratio of the base
length to the base
width. In one example, a heat gain rate of the insulating device can be
approximately 1.0-
1.5 degF/hr.
[139] Another example method of forming an insulating device may include
forming an inner
liner first portion and an outer shell first portion, securing the inner liner
first portion and
the outer shell first portion to a sealable closure to form a cap assembly,
forming an inner
liner second portion and securing the inner liner second portion to the inner
liner first
portion to form an inner liner, forming an outer shell second portion, rolling
a rectangular
foam portion to form a first cylindrical foam portion and securing a foam base
portion to
the first cylindrical portion to form a foam assembly, inserting the foam
assembly into the
outer shell second portion, inserting the inner liner into the foam assembly,
and stitching
the outer shell first portion to the outer shell second portion. The inner
liner first portion
and the outer shell first portion can be welded to the closure. The closure
can be
provided with at least one flange and the flange can be secured to a bottom
surface of the
outer shell first portion and a top surface of the inner liner first portion.
The foam can
float between the outer shell second portion and the inner liner second
portion.
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[140] An example portable insulating device may include an outer liner, an
inner liner forming
a storage compartment, a foam layer in between the outer and inner liner. The
foam layer
can be adapted to provide insulation. The example portable insulating device
may also
include an opening extending through one of the outer layer and the inner
layer and a
closing means for substantially sealing the opening. The closure can be
substantially
waterproof.
[141] In one example, a portable cooler may include an aperture on the top of
the cooler that is
opened and closed by a zipper apparatus which allows access to a chamber
within the
cooler. The aperture prevents any fluid leakage out of the cooler if the
cooler is
overturned or in any configuration other than upright. The zipper assembly
also prevents
any fluid from permeating into the cooler chamber if the cooler is exposed to
precipitation, other fluid, or submersed under water.
[142] An example method of assembling a zipper apparatus and aperture
configured to be
impervious to water or other liquids and fluids can include attachment of a
waterproof
zipper via material welding to both an outer shell and an inner liner. This
method may
result in a chamber impervious to water and other liquids when the zipper
apparatus on
the aperture is sealed.
[143] In one example, an insulating device may include an outer shell, an
inner liner forming a
storage compartment, a foam layer floating formed in between the outer and
inner liner,
the foam layer providing insulation, an opening extending through the outer
layer and the
inner layer, a closure adapted to substantially seal the opening, the closure
being
substantially waterproof so as to resist liquid from exiting the opening when
the insulating
device is in any orientation. In one example, the top portion of the outer
shell
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can have a first perimeter circumference in a first configuration. The outer
shell may
include a bottom portion, the bottom portion of the outer shell can have a
second
perimeter circumference in a second configuration that is different from the
first
configuration, and the first perimeter circumference can be equal to the
second perimeter
circumference. The first configuration and the second configuration can be
both oval
shaped. In one example, the insulating device may include an upper wall and a
base, the
upper wall can define an upper wall circumference, an upper wall length and an
upper
wall width, and the base can define a base circumference, a base length and a
base width.
The upper wall circumference can be equal to the base circumference and the
ratio of the
upper wall length to the upper wall width can be greater than the ratio of the
base length
to the base width. The cold retention time of the insulating device can be
approximately
11 to 20 hours. However, in one example the cold retention time can be 11 to
15 hours.
In another example the cold retention time can be approximately 12.24 hours.
The heat
gain rate of the insulating device can be approximately 1 to 1.5 degF/hr, and,
in one
particular example, the heat gain rate can be approximately 1.4 degF/hr. The
storage
compartment can be configured to maintain a liquid therein while inverted for
greater
than 15 minutes. In one particular example, the storage compartment can be
configured
to maintain the liquid for a period of greater than 30 minutes therein when
inverted and a
half of a volume of the storage compartment is filled with the liquid.
[144] In one example, the insulating layer can be floating freely in between
the outer shell and
the inner liner. The insulating layer can be formed of closed cell foam, and
the insulating
layer can be made of a NBR and a PVC blend. In one example least a portion of
the
insulating layer can be constructed with an EVA foam layer. The closure can be
a zipper
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assembly comprising a plurality of zipper teeth, and the zipper teeth can be
formed of
plastic.
[145] In one example, the outer shell and the inner liner can be made of a
double laminated
TPU nylon fabric. The outer shell further can include at least one of a strap
or handle.
The outer shell can include at least one ring for securing the insulating
device. The
insulating layer can be configured to maintain an internal temperature of the
insulating
device below 50 degrees Fahrenheit for 65 to 85 hours. The closure can be
formed with a
first flange and a second flange and the outer liner can be secured to top
surfaces of the
first flange and the second flange. The inner liner can be secured to bottom
surfaces of
the first flange and the second flange. The outer liner and the inner liner
can be
connected to the closure by a polymer weld. In one example, the closure can be
watertight up to 2 to 14 psi above atmospheric pressure. A loop patch may also
be
provided on the insulating device.
[146] In another example, an insulating device may include an outer shell, an
inner liner
forming a storage compartment, a foam layer floating in between the outer and
inner
liner, which provides insulation, an opening extending through the outer layer
and the
inner layer, a closure adapted to substantially seal the opening. The closure
can be
substantially waterproof so as to prevent liquid from exiting the opening when
the
insulating device is inverted for a period of greater than 15 minutes. The
heat gain rate of
the insulating device can be approximately 1.0 to 1.5 degF/hr. The insulting
device can
include at least one handle. The at least one handle can be configured to
support 100 lbs.
to 300 lbs. of weight for 1 to 10 minutes without showing signs of failure. In
one
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example, the insulating device can be configured to withstand 35 lbs. to 100
lbs. of
puncture force.
[147] An example method of forming an insulating device can include forming an
inner liner
first portion and an outer shell first portion, securing the inner liner first
portion and the
outer shell first portion to a sealable closure to form a cap assembly,
forming an inner
liner second portion and securing the inner liner second portion to the inner
liner first
portion to form an inner liner, forming an outer shell second portion, rolling
a rectangular
foam portion to form a first cylindrical foam portion and securing a foam base
portion to
the first cylindrical foam portion to form a foam assembly, inserting the foam
assembly
into the outer shell second portion, inserting the inner liner into the foam
assembly, and
securing the outer shell first portion to the outer shell second portion to
form the outer
shell. The method may also include securing a closure configured to be a
barrier against
fluid penetration in and out of the inner vessel and forming a waterproof
polymer weld
between the closure and the inner shell and the closure and the outer shell
when the
closure, the outer shell, and the inner liner are lying in a flat plane.
[148] In an example, the inner liner first portion and the outer shell first
portion can be secured
to the closure. The closure can be provided with at least one flange, and the
flange can be
secured to a bottom surface of the outer shell first portion and a top surface
of the inner
liner first portion. The foam can freely float between the outer shell second
portion and
the inner liner second portion. The outer shell and inner shell are only
connected to the
closure and not to the insulating layer between the outer shell and inner
liner. The outer
shell can be formed of a 'TPU nylon material, and the inner liner can be
formed from a
TPU nylon material. The closure can include a first flange and a second
flange. The
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outer liner can be secured to top surfaces of the first flange and the second
flange, and the
inner liner can be secured to bottom surfaces of the first flange and the
second flange.
The top of the insulating layer can have a first perimeter circumference. The
bottom of
the insulating layer can have a second perimeter circumference. The first
perimeter
circumference can be equal to the second perimeter circumference.
[149] In one example, an insulating device can include an outer shell defining
a sidewall, an
inner liner forming a storage compartment, an insulating layer positioned in
between the
outer shell and the inner liner, the insulating layer providing insulation for
the storage
compartment, an opening extending through the outer shell and the inner liner,
and a
closure adapted to substantially seal the opening, the closure being
substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device is in
any orientation. The insulating device may include a vertically extending
front facing
surface and the closure can be located on the front facing surface. A cross
section of the
insulating device can approximate a pentagon in an extended position, and a
cross section
of the insulating device can approximate a trapezoid in an extended position.
The
insulating device may also include a base, and the insulating layer can
insulate the base.
The base may also include an additional insulating layer.
[150] The insulating device may also include a fold-down portion configured to
cover the
closure. The fold-down portion comprising a first section and a second section
and
wherein the first section is free of the insulation layer and the second
section includes the
insulation layer. The fold-down portion can be at least partially free of
foam. The fold-
down portion can be configured to be secured to the sidewall. The fold-down
portion can
include at least one hook and the sidewall can include at least one loop. The
hook can be
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configured to engage the loop to secure the fold-down portion to the sidewall.
The fold-
down portion can be secured to the sidewall, and the fold-down portion may
extend at
least partly in a substantially horizontal direction. The fold-down portion
may define a
first width, and the closure extends across at least 95% of the first width.
The fold-down
portion may also include a handle configured to be grasped by a user when the
fold-down
portion is secured to the sidewall.
[151] The insulating layer may include a foam material. The insulating layer
may include a
first portion and a second portion, and the second portion can be formed
thicker than the
first portion. The insulating layer can be at least partly formed in a shape
of a T. The
insulating layer can be at least partly formed of a first rectangle and a
second rectangle
and the first rectangle can have a larger area than the second rectangle. The
first
rectangle can have a first rectangle width and the second rectangle can have a
second
rectangle perimeter. The first rectangle width can approximates the second
rectangle
perimeter. The second rectangle can extend into the fold-down portion. The
insulating
layer can have a first height and a second height and the first height can be
greater than
the second height. A majority of the insulating layer can extend to the second
height.
[152] A method of forming an insulating device may include forming an inner
liner defining a
storage compartment, forming an outer shell defining a sidewall, placing an
insulating
layer in between the outer shell and the inner liner, the insulating layer
providing insulation
for the storage compartment, placing an opening in the inner liner and the
outer shell, and
placing a closure between the inner liner and the outer shell. The closure can
be adapted
to substantially seal the opening, and the closure can be substantially
waterproof so as to
resist liquid from exiting the opening when the insulating device is in
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any orientation. The method may also include forming a fold-down portion
configured to
cover the closure, providing the fold-down portion with a first section and a
second
section. The first section can be free of the insulation layer and the second
section can
include the insulation layer. The fold-down portion can be at least partially
free of foam.
The fold-down portion can be configured to secure to the sidewall. The method
may also
include forming the insulating layer at least partly in the shape of a T,
forming the
insulating layer at least partly of a first rectangle and a second rectangle,
and forming the
first rectangle of a larger area than the second rectangle. The method may
also include
extending the second rectangle into the fold-down portion and providing the
insulating
layer on a base and providing an additional insulating layer along the base.
[153] In another example, an insulating device can include an outer shell
defining a sidewall, an
inner liner forming a storage compartment, and an insulating layer positioned
in between
the outer shell and the inner liner. The insulating layer can provide
insulation for the
storage compai __ unent. The insulating device can include an opening
configured to allow
access to the storage compartment and a closure adapted to substantially seal
the opening.
The insulating device can include a binding material, and the binding material
can be
placed over a joint between the inner liner and the outer shell. The binding
material can
be stitched onto the insulating device, and the stitching can create openings
into the outer
shell for venting air trapped between the insulating layer and the outer
shell. The binding
material can create at least one strap for holding the insulating device. The
binding
material can include a first folded portion attached to the outer shell and a
second folded
portion, and the second folded portion can form a strap.
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[154] The insulation device can approximate a trapezoid from a front view and
can
approximate a conical shape from a side view. In one example, the insulating
device
increases from 0 F to 50 F in a duration of 70 hours or greater when filled
with 0.52 lbs.
of ice per each quart in capacity of the insulating device.
[155] The closure can be substantially waterproof so as to resist liquid from
exiting the opening
when the insulating device is in any orientation. In one example, the
insulating device
can be configured to withstand being held inverted for 15 minutes without any
water
escaping or leaving the storage compartment. The closure can be configured to
stay in
the opened position when the closure is not sealed. The closure can be a
zipper. In one
example, the closure extends at least 80% of the length of the insulating
device when
measured along the closure. The length of the closure can be longer than the
length of
the bottom of the insulating device, and the length of the closure is at least
5% longer
than the length of the bottom of the insulating device. The insulating device
can include
a vertically extending front facing surface, and the closure can be located on
the front
facing surface. A handle can be located on a rear facing surface opposing the
front facing
surface.
[156] In the example insulating device, the insulating layer can comprise a
foam material. The
insulating layer can comprise a first portion and a second portion, and the
second portion
can be formed thicker than the first portion. The insulating layer can be at
least partly
formed of a first rectangle and a second rectangle, and the first rectangle
can have a
larger area than the second rectangle. The insulating layer can have a first
height and a
second height, and the first height can be greater than the second height. In
one example,
a majority of the insulating layer can extend to the second height. In
addition or
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alternatively, the front of the insulating layer can extend to the second
height and the rear
of the insulating layer extends to the first height. The insulating device can
include a
base, and the insulating layer can insulate the base. Also the base can
include an
additional or separate insulating layer. In one example, the insulating layer
can cover
80% or more of the inner liner covering the storage compartment or the
insulating layer
can cover 90% or more of the inner liner covering the storage compartment.
[157] In another example, a method of forming an insulating device may include
forming an
inner liner the inner liner defining a storage compartment, forming an outer
shell defining
a sidewall, placing an insulating layer in between the outer shell and the
inner liner, the
insulating layer providing insulation for the storage compartment, placing an
opening in
the inner liner and the outer shell, placing a closure between the inner liner
and the outer
shell, the closure adapted to substantially seal the opening, the closure
being substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device is in
any orientation. The method can also include forming the insulating layer at
least partly
of a first rectangle and a second rectangle and forming the first rectangle of
a larger area
than the second rectangle. The method can also include providing the
insulating layer on
a base and providing an additional insulating layer along the base.
[158] The present invention is disclosed above and in the accompanying
drawings with reference
to a variety of examples. The purpose served by the disclosure, however, is to
provide
examples of the various features and concepts related to the invention, not to
limit the
scope of the invention. One skilled in the relevant art will recognize that
numerous
variations and modifications may be made to the examples described above
without
departing from the scope of the present invention.
