COOLER WITH OPEN VOLUME CONTROL AND CONTENTS SECUREMENT

Abstract

A cooler with an open volume minimization system suitable for use in harsh conditions with extreme motions such as an off-road vehicle. The open volume minimization system includes a contents engagement portion that may extend from a cooler sidewall and/or a lid to reduce the open volume and constrain the contents in the cooler. Manual or powered means can lower and retract the contents engagement portion. The engagement portion may be part of an expandable bladder system integrated with the cooler. Inflation of the bladder moves the engagement portion to the contents minimizing sloshing by reducing the open volume in the interior and by securing the contents. Elastomeric strap latches under tension may keep the lid securely latched.

Description

FIELD OF THE INVENTION

This invention relates to enclosed or semi-enclosed containers. More specifically, the present invention relates to a cooler with adjustable open volume control and contents stabilization.

BACKGROUND OF THE INVENTION

Generally, enclosed or semi-enclosed thermally insulated containers are used to transport, among other items, food and beverage for consumption at a user's convenience. The thermal properties of such containers allow for a target temperature to be maintained for an item for durations significantly longer than if no such container were implemented. These containers are often referred to as coolers, portable fridges, frigerators, refrigerators, fridge-freezers, portable refrigerators, cold-storage boxes, iceboxes, chillers, cold storage, or thermally insulated containers.

These aforementioned coolers are typically filled at the beginning of use with an allotment of contents of the cooler, which can include but is not limited to any combination of food stuff(s), beverage(s), or other items that a user may want to keep at a preferred temperature then later filled with an appropriate cooling medium(s), i.e. ice-block(s), ice-cube(s), ice-pack(s), or the like.

Furthermore, with the growing popularity of personal recreational vehicles such as the industry leading POLARIS RZR sold by Polaris Inc., long distance road trips, overland expeditions, and the ever-rising demand for taking a boat out on a lake, there is a further demand for coolers adapted to these vehicles and usages.

Furthermore, during extreme temperatures, it is important for a user's comfort and pleasure that their cooler maintains an appropriate temperature and containment so that they can enjoy, at their leisure, the food, beverage, or chilled item. With recent improvements in cooler technology, such as coolers like POLARIS NORTHSTAR® COOLER sold by Polaris Inc., maintaining a proper temperature within a cooler is easier than ever.

SUMMARY OF THE INVENTION

The inventor has recognized that if a cooler is not filled to an appropriate volume, or once the contents of the cooler; food(s), beverage(s), other item(s), or ice, other cooling material(s) have been depleted and/or melted, there is unoccupied volume, extra room, within the cooler interior above the contents, so that the contents of the cooler can move, slosh, or otherwise thump around when the cooler is in motion. Particularly in the context of off-roading vehicles, the inventor has recognized this is highly undesirable to have a high open volume to contents volume in the interior of a cooler as it may cause beverage or food spillage, dented cans, broken bottles, or water-soaked Wagyu A5 steak. Moreover, in many conventional coolers, the violent movement of the contents with respect to the cooler can cause opening of the cooler lid and ejection of contents. Moreover, in cases where the cooler is large with respect to the vehicle, and carried in an open region, such as the back cargo area of a side by side recreational vehicle, or on a motorcycle, even where the cooler is well secured to the vehicle, the handling characteristics of the combination vehicle and cooler can be affected with shifting of the contents in the cooler. Where a cooler is form fit to the cargo area of a vehicle, it may be maximally sized for contents for an extending camping trip. Where the user wants to have simple beverages or food for a day trip, the ratio of open volume to contents volume may be excessively high creating a significant undesirable “sloshing” condition. The inventor has also recognized that the shifting of, sloshing of, contents in a cooler that is not well secured in a vehicle can increase the probability of the cooler shifting, moving, dislocating, and potentially exiting the vehicle. The inventor has recognized that a solution would be desirable to address these issues, in particular providing a cooler with a means to minimize the ratio of open volume to contents volume in the interior of the cooler accommodating variable contents volumes. Further, said means will ideally restrain the contents of the cooler and can accommodate variable and changing contents volume. The inventor has devised such means that renders the cooler contents generally motionless with respect to the cooler minimizing potential damage to the cooler contents and minimizing the shifting, moving, and/or potential dislocating the cooler with respect to an off road vehicle.

In embodiments, specific means are provided to minimize the open volume in a cooler above the contents and to restrain cooler contents, the means may be variable in size, easily or automatically adjustable, so that with a change in the volume of the stored contents during use and/or transportation, securement of the contents is continually maintained.

Embodiments of the invention are directed to a system for minimizing open volume in a rigid walled transportable cooler, that is, the non-contents open area above the contents in the storage area of the cooler, effectively minimizing the ratio of open volume to stored contents volume. The contents generally includes the beverages, food, ice, ice packs, and the like. Ice may be constantly melting during use/storage reducing the volumetric size of the contents. In embodiments, the cooler has a container portion formed of a rigid bottom and rigid side walls defining an open top. A hinged cover closes the open top. The bottom and sidewalls of the container portion generally being unitary, that is with an exterior and interior polymer surface walls and with insulating material between the exterior and interior polymer surface walls. In embodiments, the system for minimizing open volume comprises an expandable and retractable volume occupying system. In embodiments, the system for minimizing open volume comprises an inflatable and deflatable volume occupying system, for example one or more inflatable bladders or sacks. In embodiments, portions of the system are integrated with the cover and extend adjustably downward from the cover. In embodiments, the system may have an extending and retracting portion, such as a plate that is operable from exterior the closed cooler or that automatically extends as contents volume decreases. In embodiments, the inflated bladders are maintained in contact with the contents by the lid, which is securely latched utilizing elastomeric latch straps, secured under tension. In embodiments, alternate latches that do not release without operator actuation may also be utilized.

In embodiments, the cooler is specifically adapted to be used in high shock loading environments, such as in off-roading applications where the cooler is readily securable to a cargo area in a recreational vehicle, such as a RZR all-terrain vehicle or a Ranger utility vehicle. The cooler container portion may have a flange formed at the upper margins of the side walls and the lid conformingly shaped to the flanged open top. The flange and/or lid having attachment locations for tie downs or bungees for securement to the recreational vehicle. The lid latchable to the container portion with elastomeric straps which operate to maintain to the lid closed with the added lid opening forces provided by the system for maintaining minimal open volume. The container portion of the cooler having side wall recesses with which may receive pneumatic or fluid pumps and/or control means.

In embodiments, the means for minimizing open volume may be a bladder system with an expandable bladder providing minimal open volume in the cooler. The bladder system includes at least one material filled or fillable bladder, wherein at least a portion of the at least one material filled or fillable bladder remains either in contact with, or generally close to, the contents of the cooler in order to prevent unwanted motion of said contents. In embodiments, the expandable bladder system includes at least one material valve system allowing a flow of material into the material fillable bladder to expand the material fillable bladder to the appropriate size. In another embodiment of the invention, the means for minimizing open volume in the cooler is provided by a movable plate or panel member that allows a user to secure the contents of the cooler by applying a compressive pressure on the contents between the plate or panel member and the base, lid, or one of the sidewalls of the cooler. In embodiments the movable plate or panel member is combined with an expandable bladder.

In embodiments, the interior cavity of the cooler is defined interior walls that are movable inwardly and retractable. The side walls and bottom wall may be joined by flexible water impermeable sheet material that is closed at the top wall margins and the bottom wall. The interior is defined by a continuous wall of the flexible material but one or more walls have flexible portions that accommodate the inward and outward movement of the walls provide a reduction in the open volume of the container portion.

In embodiments, the material used within the expandable bladder system may be flowable material, such as fluid, such as air, or generally incompressible fluid, such as liquids, or a granular or beaded material, or a combination of these. The material may be a coolant provided at a below ambient temperature, an insulator with low heat conductivity or other flowable materials. In embodiments, the expandable bladder system may include a plurality of material fillable bladders. In embodiments, a material filling system allows a user to pass material through the material valve system into the material bladder thereby expanding the volume of the bladder. The material filling system can either be manually, electrically, hydraulically, or pneumatically operated to move the specified material from outside of the material fillable bladder to inside the material fillable bladder. The material filling system may be by operator actuation or by automatic means.

In embodiments, the expandable bladder or bladder system may be integrated into the lid, one or a plurality of the side walls, or the base of the cooler within the cooler cavity, or any combinations thereof. In embodiments, the expandable bladder system comprises a movable divider configured to divide the cavity into a plurality of compartments, for example a contents compartment and a compartment occupied by a filled bladder. Additionally, a bladder may be added above the contents in the contents compartment. The lid securely latchable to the container portion with elastomeric straps for tightly constraining the bladder system and contents in the cooler.

In embodiments, the rigid cooler can have rigid exterior walls and have an interior or cavity defined in part by one or more movable interior walls that can minimize the non-contents volume of the cooler. The movable walls can be the side walls or a wall movable from the top of the cooler, as part of the lid. In embodiments, the fillable bladders may have open cell compressible foam as a material or other compressible material such that evacuating the air in the bladder reduces the volumetric size of the bladder. Such bladders then can be “inflated by reducing the vacuum on the bladder, for example allowing the air pressure in the foam to return to atmospheric air pressure in the previously compressed material thereby allowing the compressed material to expand filling the non-contents volume of the cooler. Rather than using a compressor to inflate the fillable bladders, a suction or vacuum pump is utilized to deflate the fillable bladders.

In embodiments, the expandable bladder system includes a means to allow for continuously monitoring and pressurizing the material fillable bladder during use or operation which may allow the minimization of open volume to occur automatically as the volume of the contents diminishes, for example as ice melts. In embodiments, as the contents volume contracts and the open volume increases, a bladder with a specific fixed volume that fills the otherwise open volume above the contents,

In embodiments, the open volume minimization system is one or more plate-like members. The plate like member applies a compressive force between the plate-like member and one or a plurality of the sidewalls, lid, or base of the cooler. In such an embodiment, a translation member may be utilized to help direct the motion of such a plate-like member to move in a desired fashion. The plate like member may seat on the contents thereby minimizing the open space above the contents. In embodiments, the positioning of the plate like member and downward movement may be facilitated by gravity. The plate like member may be placed at the top of the cooler contents when it is filled and as the volume of the contents decreases, such as from ice melting, the plate like member may move downward by gravity such as by sliding or by linkages. The mechanisms supporting the plate like member can have a impediment to the retraction of the plate, such as a ratchet mechanism, that upward movement of the plate like member during transport is precluded or inhibited. The mechanism may be configured such that the rough ride of the vehicle into which the cooler is placed and/or mounted, facilitates the downward movement of the plate towards the bottom of the cooler.

In embodiments, an open volume minimization system is an expandable bladder system capable of being used in many instances outside of coolers, in uses such as shipping and receiving, use in semi-trucks refrigerated or otherwise, or any situation where you do not want items to move within a cavity.

A feature and advantage of embodiments of the invention is that the open volume above the contents of the cooler as the contents are reduced in volume by usage, ice melting, compacting of the contents, is minimized, securing the contents therein, minimizing sloshing and movement, protecting the contents from damage.

A feature and advantage of embodiments is that with the minimization of the open volume above the contents, particularly with air bladders, the efficiency of the cooler is improved by minimizing air flow and conduction between the chilled contents and the lid and sidewall interior surfaces.

A feature and advantage of the invention is that coolers with the means for securing the contents are highly suitable for use in coolers anchored within off road vehicles. Moreover, such coolers typically have high integrity latching systems, for example, coolers that are “bear proof” due to the strength of the cooler walls and the robust latching systems with elastomeric strap latches. These are highly suitable for using open volume minimization systems, such as inflatable bladders, in that bladders may be inflated in the latched cooler and even where there is force being exerted on the inside surface of the lid of the cooler, due to inflation of the bladder, the cooler remains closed and the cooler contents secured. In embodiments, systems providing open volume minimization systems may utilize subsystems of the off road vehicle for providing power for operating the open volume minimization systems.

In embodiments, a cooler having open volume minimization means comprises a container portion and a hinged lid with a latch, the container portion having sidewalls with an interior polymer wall and an exterior polymer wall and foam insulation therebetween and having an empty open volume from 12 quarts (11.4 liters) to over 400 quarts (378.6 liters). In embodiments, the cooler having an empty open volume of 30 quarts (28.4 liters) to 100 quarts (94.6 liters). In embodiments, the cooler having an empty open volume of from 40 quarts (37.9 liters) to 55 quarts (52.0 liters). In embodiments, the cooler having an empty open volume of less than to 55 quarts (52.0 liters). “Empty open volume” when used herein means with the cover or lid closed and the cooler empty. In embodiments, the open volume minimization means may reduce the open volume of the cooler by at least 50%. In embodiments, the open volume minimization means may reduce the open volume of the cooler by at least 70%. In embodiments, the open volume minimization means may reduce the open volume of the cooler by at least 80%. In embodiments, the open volume minimization means may reduce the open volume of the cooler by at least 90%.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side by side off road or utility vehicle with a cooler adapted for same in accord with embodiments.

FIG. 2A is a cooler suitable for such off road or utility vehicles with components of embodiments of the invention illustrated schematically.

FIG. 2B is a cooler suitable for such off road or utility vehicles show in cross-section and schematically.

FIG. 2C is a cross sectional view of the wall of a cooler such as illustrated in FIGS. 2A-2B.

FIG. 3A is a top perspective view of an embodiment of a prior art cooler.

FIG. 3B is a side cross sectional view of embodiment of a prior art cooler containing items.

FIG. 4A is cooler with the lid open that is suitable for such off road or utility vehicles with components of embodiments illustrated by dashed lines.

FIG. 4B is the cooler of FIG. 4A with the lid closed.

FIG. 5A is a front elevation view of an expandable bladder system.

FIG. 5B is a cross section of the expandable bladder system of FIG. 5A in a filled or inflated state.

FIG. 5C is a front elevation view of another expandable bladder system with the bladder deflated.

FIG. 5D is a cross section of the expandable bladder system of FIG. 5C with the bladder in an inflated state.

FIG. 6A is a perspective view of another expandable bladder within a bladder.

FIG. 6B is a cross sectional view of the bladder within a bladder of FIG. 6A.

FIG. 6C is a perspective view of the bladder of FIG. 6A further inflated.

FIG. 6D is a cross sectional view of the bladder of FIG. 6C.

FIGS. 7A-7D are partial cross sections of embodiments of expandable bladder systems with an inflatable bladder and a valve system.

FIG. 8A is a perspective view of a cooler with an open volume minimization system.

FIG. 8B is a cross sectional view of the cooler of FIG. 8A with the open volume minimization system actuated constraining the contents of the cooler.

FIG. 9A is a perspective view of an open cooler with a open volume minimization system attached to the lid.

FIG. 9B is a cross sectional view of the cooler of FIG. 9A with the lid closed.

FIG. 9C is the cross sectional view of FIG. 9B with the open volume minimization system actuated.

FIG. 10A is a cross sectional view of a cooler with an embodiment of an open volume minimization system.

FIG. 10B is the cross sectional view of FIG. 10A with the open volume minimization system actuated.

FIG. 11A is a cross sectional view of a cooler with an open volume minimization system attached to the container portion.

FIG. 11B is the cross sectional view of FIG. 11A with the open volume minimization system actuated.

FIG. 11C is a perspective view of a cooler with the open volume minimization system such as illustrated in FIGS. 11A and 11B.

FIG. 11D is the cooler of FIG. 11C with the open volume minimization system actuated.

FIG. 12A is a cross-sectional view of a cooler with an open volume minimization system shown schematically.

FIG. 12B is a cross-sectional view of a cooler with an open volume minimization system.

FIG. 12C is a cross-sectional view of a cooler with an open volume minimization system.

FIG. 12D is a cross-sectional view of a cooler with an open volume minimization system shown schematically.

FIG. 13 is a partial cross-sectional view of a cooler with a hand operated pump integrated into the cooler lid.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 3A and 3B depict a generic prior art cooler 100 in which a user may transport among other items, food and beverages for consumption at a user's convenience within the cooler's cavity 101. The cooler generally has a container portion 102 that has four insulated side walls 103 unitary with a base configured as an insulated bottom wall 105. The container portion having an open top 106. An insulated cover or lid 107 closes the open top and is hinged to the container portion with hinges 110. The cooler 100 has a total volume 111 with the lid closed and no contents. Contents 113 in the cooler occupies a contents volume 115. Above the contents and below the lid is an open space 117 that defines an open volume or non-contents volume 118. The contents 113 of the cooler, can include but is not limited to any combination of food stuff(s), beverage(s), or other items that a user may want to keep at a preferred chilled state and includes cooling medium(s), i.e. ice-block(s), ice-cube(s), ice-pack(s), or the like. This open volume 118 may be caused by a user not filling the entire volume of the cavity 101 with contents 113 or a removal and/or using some of the contents 113 within the cavity 101. The open volume can change as ice melts and portions of the contents are removed.

Referring to FIGS. 1-2B a cooler 120 has an open volume minimization system which is also a contents constraint system 126 that is particularly suited to environments where cooler is subjected to harsh conditions and severe motion, such as when attached to an off road vehicle 122. The cooler generally has a cooler housing 129 which includes has a container portion 130 and top cover or lid 131. The container portion comprising sidewalls 132 and a bottom wall 133. The top cover 131 having latches 138, 140. Attachment structure 141 on the cooler may receive straps, bungee cords, brackets, or tie downs 143 for securing the cooler to the vehicle 122. The open volume minimization system and contents restraint system 126 is illustrated generally and schematically on the cooler 120 with dashed lines and has a lower engagement portion 146 in a solid line that is extendable to contact contents 148. The engagement portion is moved by way of an actuation portion 150. A power and/or control unit 151 may be operatively connected to the actuation portion. The system is actuated to minimize the open volume 152 above the contents 148. Specifically, the volume defined from the contents to the inner surface of the lid when no open volume minimization system is present, and from the contents to the contents engagement portion when a volume minimization system is provided.

The contents 148 may be canned beverages, food, ice, ice packs, coolant packs and the like. The actuation portion 150 may be a pneumatic or fluid pump, or other material pump as described below, or may be a mechanical mechanism powered by a motor or manually operated, that extends and retracts the engagement portion 146. The actuation portion may be exteriorly mounted on the cooler, may be within the lid, or sidewalls, or may be in the interior. The power and/or control unit 151 may be an air pump, have control and processing circuitry, may have a user interface, and have batteries or connection means for external power. A sensor 153 or sensors may be positioned in the interior of the cooler, for example in association with the actuation portion, to detect the status of the contents restraint system and/or status of the contents, for example the position of the engagement member 146, the pressurization of an actuator portion configured as a pressurized bladder, the existence of motion in the cooler interior, and/or temperature. The sensor 153 may have a connection, such as by wiring 154, to the power and/or control unit to provide data to display, cause a response such as further actuation of the actuator portion and movement of the contents engagement portion 146. The lower engagement portion 146 can be part of a bladder, a plate, a movable wall or a combination of same as described below. Also, connection means 160 may be provided for connecting to vehicle power or other external power and means 164 for connecting to vehicle compressed air or other source of air pressure or other media, including orally blown-in air, may be provided. See, in particular, FIGS. 2A and 2B. A user interface may include an actuation switch 167, such as an electric switch, which may be installed and exteriorly exposed on the cooler housing 129 or elsewhere on the vehicle 122.

Referring to FIGS. 2B and 2C, such coolers typically have rigid insulated side walls 132, an insulated bottom wall, and an insulated lid, each formed by a thin generally rigid interior layer 172 of a polymer and exterior layer 174 of the polymer, such as polyethylene or polypropylene, and a polymer foam 176 in between the interior and exterior layers, such as a polyurethane foam or expanded polystyrene, for example. Also, see U.S. Patent Application and Patent Nos. 2018/0153151; 7,140,507; and 10,676,267, illustrating coolers with features suitable for off road or harsh use, all of which are incorporated by reference herein for all purposes.

FIGS. 4A and 4B depict another configuration of a cooler 200 illustrating embodiments of the invention and adapted for harsh environments. The cooler has a housing 210 comprising a container portion 212 and lid 214. The container portion having sidewalls 216, a bottom wall 218, an open top 220, a flange 221 surrounding the open top 220. Structure 221, such as apertures formed in the flange, may be used for securement to an off road or utility vehicle. Elastomeric latches 223 are utilized to secure the lid to the container portion 212. An open volume minimization system 226 is shown schematically by the dashed lines where components of the system may be positioned. Recesses 230 defined on the exterior of the cooler may be utilized for components 231 of the open volume minimization system. Similarly, recesses on interior surfaces of the side walls, not shown in these views, may also be utilized for the components of the open volume minimization system. In embodiments, attachment means, such as hook and loop material pads 240, may be attached to the interior surfaces of the side walls to receive the components of the open volume minimization system, such as bladders or extendable panels.

FIGS. 5A and 5B depict an open volume minimization system 300 that includes a volumetrically expandable bladder 301 with tubing 302 extending therefrom suitable for use in a cooler. A valve 305 may be on the end of the tubing. The material fillable bladder 301 may be a configured as a bag, pouch, balloon, or similar device capable of retaining a volume filling material. The bladder 301 may be made from any material such that the bladder expands as the volume of the fill material 303 is added to it and the bladder relaxes back to its original shape after the fill material 303 is removed. Suitable materials for the material fillable bladder 301 include rubber, EDPM, Silicone, Flexible PVC, neoprene, SBR, nitrile rubber, butyl rubber, sulfide rubber, methyl rubber, silicone rubber, or other elastomers with similar properties. In embodiments, the material is configured as a flexible film or flexible sheet material. In embodiments the surface area of the bladder may significantly increase as the material stretches under the fill pressure. The material fillable bladder 301 is preferably made of a material and thickness that is both durable and puncture resistant, yet pliable enough to fill a variety of shapes and sizes. Preferably, the material fillable bladder 301 is made from an impermeable liquid tight and airtight material. The material fillable bladder 301 is filled with a fill material 301, such as air, that allows the material fillable bladder 301 to expand in volume so that when it is placed with the cavity 101 of a cooler 100 and is filled with fill material 301, the material fillable bladder 301 fills the open space between the cooler's lid and/or sidewalls and the contents of the cooler 100.

Referring to FIGS. 5C and 5D, in embodiments, the bladder 320 may be formed from the flexible polymer sheet material that has minimal stretch under pressurization. Deflated, the bladder is compact and can be flat, with pressurization it transforms into a non-spherical geometric shape such as a rectangular prism with rounded corners. With substantially non-stretching material, once full the volume of the bladder stays approximately the same under increasing pressure. Additional polymers that may be suitable for bladders include thermoplastic polyurethane (TPU), thylenevinylacetate/polyethylene copolymer, polyester elastomer (e.g. Hytrel® material available from DuPont), polypropylene, polyethylene, dacron/polyester, polyvinylchloride, polyvinyl acetate, Buna-N, Buna-S, polystyrene, ethylene propylene, polybutadiene, chlorfulfonated polythylene, nylon, polyester, or biaxially-oriented polyethylene terephthalate (e.g., Mylar® film), and others. Fabrics may be coated or impregnated with polymers for providing impermeable bladder material that does not significantly stretch under pressurization.

The material fillable bladder 320, particularly when filled, such as by inflation with air, may be of any shape and size suitable to fill the open space 201 with the cooler. The material fillable bladder 301 may be circular, spherical, rectangular prism, cuboid, cylindrical, pyramid, or any other three-dimensional shape. Ideally the material fillable bladder 320, when filled, would have a shape similar to that of the cooler cavity 101 in which it is to be used. It is also contemplated that the material fillable bladder 301 is able to expand to at least the volume within the cooler 101 when no contents 203 are in the cooler 100.

FIG. 6A-6D shows an expandable bladder system 360 that includes a bladder 366 in a bladder 368. The first or inner bladder 366 includes a valve system 370 which is used in expanding the volume of the first inner bladder 366. The second outer bladder 368 includes a second valve system 376 which is used in filling or expanding the volume of the second outer bladder 603. This multi-bladder 360 system allows an operator to fill the first inner bladder 366 with a first fill material 369 and then fill the second outer bladder 368 with a second fill material 303. The first and second materials may be the same or different depending on the user's needs. One example, the first inner bladder 366 may be a pneumatic bladder fillable with air. The second outer bladder may be filled with a dry flowable material such as polystyrene beads. The second material valve system may be a simple threaded cap 382 that screws onto a wide mouth threaded nipple 383 joined to the bladder material. The deflated reduced volume form of FIGS. 6A and 6B can be transformed into the greater volume inflated form of FIGS. 6C and 6D. With the flowable dry material in the second bladder, the bladder system can be form fit to uneven contents structure. The bladders may have hook and loop material pads 387 attached thereto to facilitate attachment to inside surfaces of the cooler. See FIGS. 5C and 5D. In embodiments, the polymer or other material forming the first inner bladder may be relatively more stretchable than the polymer or other material forming the second bladder.

This multi-bladder 360 system allows a user to make minute adjustments to the first 366 or second bladders 368 as the contents within the cooler changes. In embodiments, if the multi-bladder 600 system was placed inside a portable powered refrigerator which were to be fitted and wired in the back of a user's off road vehicle, the system could allow for a transfer of circulated coolant through one or the other of the first or second material bladders 601, 603 via the coolant system already existing within the refrigerator.

The bladders of FIGS. 5A-6D can be loosely positioned in cooler interiors or may be attached to cooler walls such as with hook and loop material.

FIGS. 7A-7D show embodiments of portions of an expandable bladder system 400 with a material fillable bladder 401 and a material valve system 405. The material valve system 405 may include any valve capable of retaining and releasing the type of fill material 410 placed within the material fillable bladder 401. This material valve system 405 may be as simple a synching rope 412 used to contain solid fill material 410 within the material fillable bladder 401, as illustrated in FIG. 7A. Referring to FIG. 7C, the valve system 425 may include a common automotive style valve 429 such a Schrader, Presta, Woods, or Dunlop valve. These valves 429 would allow use the use of a readily available automotive, or bike pump to inflate the material fillable bladder 401 with an air 435 as the fill material. Referring to FIG. 7B, similarly, it may be desirable to use a ball, butterfly, diaphragm, gate, globe, pinch, or other fluid regulating valve 440 with a connector 441 in the material valve system 405 as it would allow the material fillable bladder 401 of the expandable bladder system 400 to be filled with a fluid fill material 410 such as water, coolant, or otherwise flowable liquid that may retain temperature at a higher insulative R-Value than a simple gas. Referring to FIG. 7D, the valve system may be an oral inflation valve such as those used in most swim toys and beach balls, which can be used to inflate an object via an operator's lung power or via an air pump.

FIGS. 8A and 8B depict a cooler 500 having a container portion 501, and a hinged lid 502. The cooler has an open volume minimization system 504 comprising an expandable bladder system 506 that includes multiple material fillable bladders 510, 512, 514, 516. The bladders can be adjustably positioned utilizing cooperating hook and loop pads or surfaces 520 on the interior wall surfaces 523 of the cooler. In embodiments, each of the multiple material fillable bladders 510, 512, 514, 516 can be independently filled through respective valve systems 525 with, for example, air 535 as the fill material. The lower bladders 512, 514, 516 may be first filled, and then the upper bladder 510 attached to the inside surface 523 of the cooler lid can be filled sufficiently to snuggly fill the open space and push the lower bladders to contact and secure the contents 548 as the lid 502 is shut and latched to the container portion 501 with the elastomeric latches 543.

In another embodiment, the multiple material fillable bladders 510, 512, 514, 516 can be connected to an air pressure source, which may either be part of a vehicle which is carrying the cooler or can be an accessory. In embodiments, the air pressure source may be attached to the cooler or an integral part of the cooler. See FIG. 8B with an air pump unit 550 mounted to the lid 502. Air lines 556, illustrated by dashed lines, may connect the bladders to the air pump unit 550. The air pump unit may have its own power source 558, such as batteries, or may be connectable to vehicle power. The lines may be interconnected, and the bladder pressure monitored by way of the lines connecting to the air pump unit. A sensor system 560 in the air pump unit can activate pressurization of the air pump upon sensing a drop in the bladder air pressures indicating the bladders need to be expanded to compensate for a reduction of the contents volume by, for example, settling of contents 548 and/or melting of the ice.

FIGS. 9A-9C illustrates a cooler 600 having a container portion 601 with a hinged lid 602, and further having an expandable bladder system 608 for open volume minimization and contents securement that includes a fillable bladder 610 that is incorporated into the lid 602 of the cooler 600. The material fillable bladder 610, when filled with air 635 as the fill material expands in a direction away from the inside surface 641 of the lid 602 into the open volume 645 and toward the bottom wall 643 of the cooler 600 until a lower engagement portion 646 of the bladder contacts and secures the contents 648 of the cooler minimizing the open volume 645 above the contents and securing the contents. Incorporating the material fillable bladder 610 into the lid 602 of the cooler 600 allows for the material valve system 652 to be placed on the top 655 or any side 657 of the cooler lid 602 allowing an operator to fill the material fillable bladder 610 while the cooler lid 603 is closed. In such an embodiment, it may be desired to include a second, one way pressure relief valve 661, opposite the material valve system 652 to regulate the pressure within the material fillable bladder 610 to a maximum desired pressure. It is further contemplated that the material fillable bladder 610, when not filled with air would recess back into the cooler lid 603 and be retained there such as by bands or belts 667. The bands or belts may be elastomeric and manually secured, for example at tabs 669 extending from the lower inside surface 641 of the lid 602, such that the retracted bladder does not occupy any significant interior volume of the cooler's cavity open interior 670 if a user does not desire to use the open volume minimization system. As described with reference to FIGS. 8A and 8B, an air pump unit 650 may be incorporated into the cooler 600, the pump unit 650 air outlet 651 may be connected directly to the bladder 610 through the lid wall, see FIG. 9B. The pump unit 650 may be integrated into the cooler by attachment in recesses on the exterior wall, either on the exterior of the lid 602 or in a recess 678 on the container portion. The lower engagement portion 646 of the bladder may have integral panels 681 attached to the interior or the bladder, or the exterior or the bladder, or embedded in the bladder forming material. In embodiments, the panels may be a thickening of the bladder forming material, the thickening providing rigidity to the thickened portions.

Referring to FIGS. 10A and 10B, in an embodiment, a cooler 700 with a container portion 701 and a lid 702, includes an open volume minimization means 706 configured as bladder system 707 with a rigid panel 709 that translates from the lid toward the bottom wall driven by an extendable and retractable portion, in this case configured as a fillable bladder 710. The bladder 710 may be provided air for extension through the tubing and valve. The bladder 710 may be separated from the open interior 722 of the cooler by a flexible sheet material 727 that is impermeable to liquids and is sealingly attached to or unitary with the interior wall surface of the lid 702 of the cooler 700. The flexible sheet material 727 may in embodiments be of a low stretch polymeric material that has an extendable wall portion 728 that has a folded or billowed portion 731 when the panel is retracted, and the extendable-retractable portion is retracted. The lower engagement portion 746 of the bladder system is the panel 709. Springs or elastic members 749 may be provided to urge the panel 709 to a retracted position as shown in FIG. 10A. In embodiments the extendable wall portion may be elastic to urge the panel to the retracted position. In embodiments, more than one rigid panel may be provided which may allow the lower engagement portion of the open volume minimization means to better conform to the shape of the upper margin of the contents. In embodiments, the bladder may be inflated by the valve system 752 as described previously or an air pump unit 750 may be utilized. In embodiments a plurality of bladders may be provided attached to the lid and the extend downward and retract. In embodiments, each of a plurality panels may have a dedicated bladder.

Referring to FIGS. 11A-11D, in embodiments, a cooler 800 having a container portion 801 and a hinged lid 802, has an open interior 822 defined at least in part by interior movable side panels 829 that are extendable from the rigid sidewalls 832 of the container portion 801. The movable side panels 829 may be extendable by actuation means 836 such as by an inflatable bladder system 840, with inflatable bladders 841. A flexible sheet material 843 may connect the movable side panels to the cooler's rigid sidewalls 832. In embodiments, the upper portion of the panel 847 may extend in further than the lower portion 848 as best illustrated in FIGS. 11B and 11D providing a tapered open interior 822 wider at the bottom 855 of the interior than the upper interior 856. This may be effectuated by more of the flexible sheet material at the top ends 861 of the movable side panels 829 than at the bottom ends 862 as well as a bladder shaped to inflate as illustrated best in FIG. 11B. This better constrains the contents and minimizes sloshing of the contents under shock and rough conditions when compared to a conventional cooler that is wider at the top of the interior than the bottom. In embodiments, all four sides may be extendable inwardly. In embodiments only one or two of the four sides may be extendable inwardly. In embodiments, each side may have a dedicated inflatable bladder. In embodiments, a single bladder may extend around two, three, or four sides of the interior sides of the cooler.

Material fillable bladders of the expandable bladder systems 400, 506, 608, 707, 841, may be filled with fill material through a variety of methods depending upon the configuration of the material valve system. The expandable bladder system's material valve system 305 may include an oral inflation valve, which allows a user to blow air directly into the bladder through a user's lungs, or through use of a pump. FIG. 7C illustrates the use of an automotive style valve, such as a Schrader valve, this would allow a user to fill the expandable bladder system with bike pump, or air compressor. Such expandable bladder systems may be connected to a vehicle's on-board compressor. Typically, a vehicle would have an onboard compressor if it included a Central Tire Inflation System (CTIS). In this embodiment the expandable bladder system 300 would include a pressure sensor inside the material fillable bladder 301 and self-regulate the pressure to a specific PSI in which the material fillable bladder 301 is applying the appropriate amount of pressure on the contents 203 of the cooler 100 such that they do not shift while the user's vehicle is in motion. The pressure sensor may continually monitor the pressure and adjust fill the material fillable bladder as necessary. For example, should the volume of the cooler cavity alter in some way, such as by ice melting, the change in pressure can cause the pump to inflate or deflate the bladder system as appropriate to limit movement of the cooler contents. In embodiments, the pressure may be regulated to be a few psi. See U.S. Pat. Nos. 9,884,522; 9,415,645; 9,387,731. Said patents are incorporated by reference herein for all purposes.

FIGS. 12A-12C illustrates a cooler 900 having a container portion 901 and a hinged lid 902 that also has a securement system and an open volume minimization system 910 integrated with the cooler 900 utilizing a manual power receiving portion 925 connecting to a translation mechanism 927 attached to a plate or panel member 930 positioned in the interior 931 of the cooler to extend and retract and to engage and secure the contents 948 of the cooler 900. The system allows an operator to translate the plate or panel member 930 from a stowed position at the lid 902 into a securing position engaging the contents. The translation mechanism 927 translates the motion provided to the manual power receiving portion into a linear motion for lowering and raising the manual actuation of the plate or panel member 930 within the cooler 900. As shown in FIG. 12B, the translation member 927 may be nut and screw mechanism 956, and the power receiving portion 925 may be configured as a hand crank 958. Rotation of the crank lowers and raises the plate or panel member 930. Multi-tiered screw and nut mechanisms that take up less vertical space would also be suitable. The translation mechanism 927 is contemplated to be any mechanical mechanism that translates a manual motion at the power receiving portion 925 into movement of the plate or panel member 930. Scissor mechanisms, rack and pinion mechanisms, linkages of various types, and other mechanisms may be utilized. Manually operated ratchet mechanisms may be utilized to move the plate or panel member. The downward motion of the plate or panel member may be facilitated or caused by gravity, with a one-way mechanism precluding or inhibiting upward movement of the plate during transport. FIG. 12C illustrates a manual air pump 970 mounted on the lid 902 that may inflate a bladder 974 that may extend and retract the plate or panel member 930.

FIG. 12D depicts the cooler 900 of FIGS. 12A-12C but utilizes an electric motor drive motor 962 rather than the manual power receiving portion 925. The drive motor connected directly or through gearing to the translation mechanism 927. The drive motor may be powered by vehicle power, a separate battery, or a battery pack 979 mounted on the cooler.

The plate or panel member 930 of FIGS. 12A to 12D may be constructed out of a variety of different materials and made to be interchangeable with alternate depending on the operator's needs. It is contemplated that the plate or panel member 930 be made out of the same material as the cooler 900, this material could range from a soft plastic to stainless steel. In embodiments, when in the stowed position, the plate or panel member 930 could be recessed into the cooler lid 903 so that it does not occupy any interior volume of cooler cavity 931 when in the retracted position. The plate or panel member may also be constructed out of a more pliable material, such as an elastic or foam-like material, that can deform slightly to accommodate contents 948 of various shapes within cooler interior 931 when the plate or panel member 930 is in the contents securing position. Similar to the material fillable bladders, the plate or panel member 930 is contemplated to be shaped in a variety of different shapes and sizes. It may be desired that the plate or panel member be circular, or hemispherical, or even spherical in certain situations. In embodiments, when the plate or panel member 930 is recessed into the cooler lid, the plate member 930 could include a sealing member around the periphery of the plate member and generally similar in shape and size to the interior of cooler interior 931, so that it would maintain a liquid tight seal around the perimeter of the plate member 930 when in the secured position. The plate like member may also be contained within a compartment defined by water impermeable flexible sheet material that extends to wall portions or the lid such that the translation portion is not exposed to water or the contents of the cooler, similar to the embodiments of FIGS. 10A-11B.

Referring to FIG. 13, in an embodiment, a hand operated air pump 1060 may be integrated with the cooler lid 1062. The bladder 1066 formed of flexible polymeric sheet material. Robust latches, such as elastomeric latches 1068 may secure the lid to the container portion 1071 such that the pressurization of the bladder will not push open the lid from the inside. The container portion having a foam insulation layer 1073 sandwiched between an inner polymeric wall 1075 and an outer polymeric wall 1076. An indicator 1074 may be present on the top of the lid indicating pressurization level. Also, a pressure release lever, switch or button 1076 may be present to relieve the pressure before opening the lid. The bladder has a lowermost engagement portion 1080 that is conforming to the contents 1084 in the cooler as illustrated by the dashed lines. Example of inflation systems, inflatable bladders, other components, mechanisms, component materials, and control systems relevant to the systems and disclosures here and that may be suitable for use with same are found in U.S. Pat. Nos. and Publication Nos. 7,290,761; 7,306,212; 7,996,940; 9,440,695; 2020/0078254; 9,884,522; 9,415,645; 9,387,731.

All of the above patents and patent publications are incorporated herein by reference in their entirety for all purposes, except for express definitions and patent claims contained therein.

The invention is not restricted to the details of the foregoing embodiment (s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.

While the aforementioned particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, that changes and modifications may be made without departing from this invention and its broader aspects. Therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention. It will be understood by those with skill in the art that if a specific number of an introduced claim element is intended, such intent will be explicitly recited in the claim, and in the absence of such recitation no such limitation is present. For non-limiting example, as an aid to understanding, the following appended claims contain usage of the introductory phrases “at least one” and “one or more” to introduce claim elements. However, the use of such phrases should not be construed to imply that the introduction of a claim element by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an”; the same holds true for the use in the claims of definite articles.

Claims

1. A cooler with an open volume minimization system, the cooler comprising: a container portion with a plurality of insulated sidewalls an insulated bottom wall defining an upper opening, an insulated lid hinged to the container portion, and a latch that secures the lid to the container portion in a closed position, the insulated sidewalls comprising a polymer exterior wall, a polymer interior wall and a foam insulative material therebetween, the closed lid and container portion defining an open interior with a volume in the range of 30 quarts (28.4 liters) to 100 quarts (94.6 liters), the volume minimization system comprising:

an expandable bladder system attached to at least one of the lid and a sidewall of the cooler, the expandable bladder system comprising at least one material fillable bladder and at least one valve system for controlling material entering and exiting the bladder,

wherein the at least one material fillable bladder is positioned within the open interior of the cooler, and

wherein the at least one material fillable bladder is configured to expand and retract within the open interior.

2. The cooler with the open volume minimization system of claim 1, wherein the at least one material fillable bladder and valve system are configured for using air as the material for expansion and contraction of the bladder.

3. The cooler with the open volume minimization system of claim 2, comprising a plurality of bladders.

4. The cooler with the open volume minimization system of claim 3, wherein the cooler has interior wall surfaces with hook and loop material thereon and the plurality of bladders each have cooperating hook and loop material thereon for attachment of each of the plurality of bladders to the interior wall surfaces of the cooler.

5. The cooler with the open volume minimization system of claim 1, wherein the expandable bladder system comprises a panel that is urged toward the bottom wall of the cooler for engagement of contents in the cooler.

6. The cooler with the open volume minimization system of claim 1, wherein the open volume minimization system may reduce the open volume of the cooler by at least 50%.

7. A cooler with an open volume minimization system comprising:

a cooler comprising a lid; a plurality of sidewalls; and a base, the cooler having an open interior;

an expandable bladder system comprising at least one bladder attached to one of the lid and container portion, the bladder inflatable and deflatable;

the bladder having at least one panel positioned to engage contents in the cooler when the bladder is inflated; and

inflation means are mounted to or extend from cooler.

8. The cooler with the open volume minimization system of claim 7, wherein the inflation means comprises an air pump attached to the cooler, wherein the air pump is one of manually or electrically operatable.

9. The cooler with the open volume minimization system of claim 8, wherein the expandable bladder system may reduce the open volume of the cooler by at least 50%.

10. The cooler with the open volume minimization system of claim 8, further comprising a sensor for monitoring air pressure in the bladder.

11. The cooler with the open volume minimization system of claim 8, further comprising a plurality of additional bladders that are inflatable by the air pump.

12. The cooler with open volume minimization system of claim 11, wherein the expandable bladder system includes a plurality of plates or panels, at least one plate or panel associated with each bladder.

13. The cooler with open volume minimization system of claim 7, wherein the plates or panels and bladders are configured to provide an open interior that when the bladders are inflated the open interior that tapers upwardly.

14. A cooler with open volume minimization system comprising:

a cooler comprising a lid; a plurality of sidewalls; and a base, all defining an open interior with an open and closable top, the cooler having a capacity of from 12 quarts (11.4 liters) to over 400 quarts (378.6 liters), the cooler having means; and

a contents securement system comprising a plate member;

an extendable and a retractable portion attached to the lid and the plate member.

15. The cooler with open volume minimization system of claim 14, wherein the plate member has a stowed position at the lid.

16. The cooler with open volume minimization system of claim 14, further comprising a manual crank and the extendable and retractable portion is configured as a screw and nut mechanism connected to the manual crank.

17. The cooler with open volume minimization system of claim 14, comprising an electric motor connecting to the extendable and retractable portion.

18. The cooler with open volume minimization system of claim 14, comprising a manual air pump and wherein the extendable and retractable portion is a bladder operative connected to the manual air pump.

19. The cooler with open volume minimization system of claim 14 having apertures at an upper rim of the container portion for securement of the cooler to a vehicle.

20. The cooler with open volume minimization system of claim 14, wherein the open volume minimization system may reduce the volume of the cooler by at least 50%.

21-46. (canceled)