Abstract:
Inserts for holding items stored in a cooler above the bottom of the cooler so that condensation or ice melt drains below the items. In one illustrative embodiment, the insert has a base portion that serves as a shelf for holding items stored in a cooler above the bottom thereof, which has a drainage structures to allow ice melt to flow underneath the base and away from the items. The base may be formed of one or more separate pieces and may be adjustable in size for use in different coolers. Adjustment features may include removably attachable extensions and base components that are slidably adjustable to form a complete base member of a desired size.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to and incorporates by reference all of the subject matter included in Provisional Patent Application Ser. No. 62/102,507, which was filed Jan. 12, 2015. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to chest coolers and to inserts for chest coolers. 
       BACKGROUND 
       [0003]    Conventional chest coolers store a coolant (typically ice or freezer packs) with items to be kept cool. As heat is absorbed by the coolant, it can melt or accumulate ambient moisture. The moisture may then accumulate in the bottom of the interior of the cooler. Generally, the items to be kept cool also sit on the bottom surface of the cooler and become moistened by the melted ice or collected condensation accumulated in the bottom of the cooler. This may be undesirable as it may affect the stored items negatively. For example, the items may become spoiled, damaged, or contaminated. This may frustrate the utility of the cooler and further create a situation that may require substantial effort to clean. 
       SUMMARY 
       [0004]    The present disclosure is directed to an insert for holding items stored in a cooler above the bottom of the cooler so that condensation or ice melt drains below the items. In one illustrative embodiment, the insert has a base portion that serves as a shelf for holding items stored in a cooler above the bottom thereof, which has a drainage structures to allow ice melt to flow underneath the base and away from the items. The base may be formed of one or more separate pieces and may be adjustable in size for use in different coolers. Adjustment features may include removably attachable extensions and base components that are slidably adjustable to form a complete base member of a desired size. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0005]    It will be appreciated by those of ordinary skill in the art that the various drawings are for illustrative purposes only. The nature of the present disclosure, as well as other embodiments thereof, may be more clearly understood by reference to the following detailed description, to the appended claims, and to the several drawings. 
           [0006]      FIGS. 1A-G  depict schematic diagrams of various elements of one embodiment of a chest cooler insert with drainage structure slats. 
           [0007]      FIG. 2  depicts a schematic diagram of another embodiment of a chest cooler insert with offset drainage structure openings. 
           [0008]      FIG. 3  depicts a schematic diagram of one embodiment of a chest cooler with a cutaway showing the insert of  FIG. 1 . 
           [0009]      FIGS. 4A and 4B  depict schematic diagram views of another embodiment of a chest cooler insert with drainage structure openings. 
           [0010]      FIG. 5  depicts a top perspective view of another embodiment of a chest cooler insert, which is adjustable for use in different size coolers. 
           [0011]      FIG. 6  depicts a front view of the top components of the embodiment of  FIG. 5 . 
           [0012]      FIG. 7  depicts a portion of the upper top member of the embodiment of  FIGS. 5 and 6 , with an expandable portion removed. 
           [0013]      FIG. 8  depicts a portion of the lower top member of the embodiment of  FIGS. 5 and 6 , with an expandable portion removed. 
           [0014]      FIG. 9  depicts a portion of the lower surface of the embodiment of  FIGS. 5 through 8  depicting the components of an elevation structure thereof. 
       
    
    
       [0015]    Throughout the description, similar reference numbers may be used to identify similar elements. 
       DETAILED DESCRIPTION 
       [0016]    The present disclosure relates to inserts for coolers. It will be appreciated by those skilled in the art that the embodiments herein described, while illustrating certain embodiments, are not intended to so limit this disclosure or the scope of the appended claims. Those skilled in the art will also understand that various combinations or modifications of the embodiments presented herein can be made without departing from the scope of the present disclosure. All such alternate embodiments are within the scope of the present disclosure. 
         [0017]    While many embodiments are described herein, at least some of the described embodiments include an insert configurable to be placed on the inside of a conventional cooler. The described embodiments facilitate gravity-fed drainage of liquids through the insert to the bottom of the cooler. In some embodiments, the insert reduces splashing of the liquid back through the insert once it has been drained to the bottom surface of the cooler. In some embodiments, the insert has adjustable feet to separate the insert from the bottom surface of the cooler and accommodate a varied amount of liquid. The insert is sufficiently strong to accommodate the weight of the contents of the cooler placed on the upper surface of the insert. 
         [0018]      FIG. 1A  depicts a perspective view of one embodiment of a cooler insert  1  with drainage structure slats  2 . The illustrated embodiment includes drainage structure slats  2 , a center portion  3 , and connector structures  4 . In the illustrated embodiment, the connector structures  4  also include size adaptation regions  5 . Although the cooler insert  1  is shown and described with certain components and functionality, other embodiments of the cooler insert  1  may include fewer or more components to implement less or more functionality. 
         [0019]    In one embodiment, the insert  1  is an insert for a conventional chest-type cooler. In other embodiments, the insert  1  is compatible with other systems in which it is desirable to allow for drainage of liquid or relatively small particulate through a surface and reduce return of the drained material through the insert  1 . In some embodiments, the insert  1  allows for drainage and reduced return of the drained material through the use of slats  2 . In the illustrated embodiment, the slats  2  are curved to allow for drainage space between the slats  2 . The slats  2  also reduce the amount of drainage material that is allowed to pass back through the slats  2 . In the illustrated embodiment, the slats  2  are turned to curve towards the center of the insert  1 . In other embodiments, the slats  2  may curve outwards or in multiple directions. The illustrated embodiment includes a center portion  3 . In the illustrated embodiment, the center portion  3  has a triangular cross-section. In other embodiments, the center portion  3  has other geometries. In some embodiments, the center portion  3  may be solid throughout or hollow or a mixture of both along the length. 
         [0020]    In some embodiments, the insert  1  may be made of a single material such as a plastic, metal, or composite. In another embodiment, each component of the insert may be made of a material chosen to reduce price, simplify manufacturing, or perform a function. For example, the entire insert  1  may be constructed of a plastic for ease of cleaning and durability, or the slats  2  and center portion  3  may be constructed of a metal while the remainder of the insert  1  is constructed of a composite material to enhance thermal conductivity via metal components and strength via composites. 
         [0021]    The illustrated embodiment also includes connector structures  4 . In the illustrated embodiment, the connector structures  4  span between the slats  2 . The connector structures  4  provide the structural rigidity of the insert  1  by joining each of the slats  2 . In the illustrated embodiment, the connector structures  4  are placed at the top of the curve of the slats  2  so as to be close to the upper surface of the insert  1 . In other embodiments, the connector structures  4  are placed at different locations along the slats  2 . In the illustrated embodiment, a single array of connector structures  4  is shown. In some embodiments, the insert  1  includes multiple sets of connector structures  4 . In some embodiments, the connector structures  4  may have a relatively small thickness in one dimension. In another embodiment, the connector structures  4  have a substantially symmetrical cross-section. 
         [0022]    In the illustrated embodiment, the connector structures  4  also include an adaptation structure  5 . In some embodiments, the adaptation structure  5  is a built-in weak region of the connector structures  4 . In some embodiments, the adaptation structures  5  would allow for removal of one or more of the slats  2  from the insert  1  to adapt the overall size of the insert  1  to fit within the internal space of a cooler. In some embodiments, the adaptation structure  5  is located near the slat  2  to be removed from the insert  1 . In other embodiments, the adaptation structure  5  is located nearer the slat  2  that will remain connected to the remainder of the insert  1 . In some embodiments, the adaptation structure  5  is a relatively thinner portion of the connector structure  4 . In another embodiment, the adaptation structure  5  is a perforated region of the connector structure  4 . In some embodiments, the adaptation structure  5  is a coupler to connect slats  2  together. In this embodiment, the adaptation structure  5  facilitates disconnection and reconnection of slat segments to the insert  1 . In other embodiments, the adaptation structures  5  are sacrificial and only allow for disconnection of the slats  2 . Other embodiments of the adaptation structure  5  facilitate adaptation of the size of the insert  1  in other ways. 
         [0023]      FIG. 1B  is a cross-sectional view of the insert  1  of  FIG. 1A . The illustrated embodiment of insert  1  includes slats  2 , center portion  3 , connector structures  4  with adaptation structures  5 , and elevation structures  6 . The slats  2  of the illustrated embodiment have a simple curved geometry. Other embodiments include other geometries (discussed further below with reference to  FIGS. 1C-1E ). In the illustrated embodiment, the slats  2  are centered around the center portion  3 . In the illustrated embodiment, the center portion  3  has a triangular cross-section. In other embodiments, the center portion  3  has non-triangular geometries. 
         [0024]    The illustrated embodiment of insert  1  also includes connector structures  4  oriented between each slat  2 . In some embodiments, the connector structures  4  are connected at the top of the slats  2 . In other embodiments, the connector structures  4  are located at a different portion of the slats  2 . In some embodiments, the connector structures  4  include an adaptation structure  5  built into the connector structure  4 . The adaptation structure  5  allows a user to disconnect a portion of the insert  1  at the adaptation structure  5 . In some embodiments, the disconnect operation involves breaking the connector structure  4  at the adaptation structure  5 . In other embodiments, the adaptation structure  5  facilitates a temporary or reversible disconnect. This would allow the user to temporarily adjust the insert  1  to accommodate a specific application. 
         [0025]    The elevation structures  6  of  FIG. 1B  are coupled to the underside of the slats  2 . The elevation structures  5  maintain the slats and the remainder of the insert  1  at some distance from the bottom of a cooler or other surface on which the insert  1  may be placed. In some embodiments, the elevation structures  6  are adjustable. This is described in more detail with reference to  FIGS. 1F and 1G . 
         [0026]      FIG. 1C  depicts a cross-sectional view of one embodiment of the slats  2  of the insert  1  of  FIG. 1A . In the illustrated embodiment, the slats  2  have a simple, single-curve geometry. In the illustrated embodiment, the slats  2  are arranged in a nested orientation so that each slat  2  is oriented similarly to the proximal slats  2 . In another embodiment, the orientation of the slats  2  may vary. For example, the slats  2  may be opposite one another or rotated 180 degrees. Other orientations may be used. 
         [0027]      FIGS. 1D-1E  illustrate alternate embodiments of the slats  2 . These figures are presented to illustrate a few potential embodiments. Other embodiments may incorporate other cross-sectional geometries and orientations or combinations of the slats  2 . 
         [0028]      FIG. 1F  depicts one embodiment of the elevation structure  6  of  FIG. 1B . In the illustrated embodiment, the elevation structure  6  includes an internal surface screw track height adjustment feature. This feature allows a user to twist the elevation structure  6  to adjust the height of the elevation structure  6  and thus the separation distance between the insert  1  and the surface upon which the insert  1  is situated. In the illustrated embodiment, the user twists all of region  7  of the elevation structure  6 . In some embodiments, the elevation structure is hollow to allow for storage space. In some embodiments, the elevation structure  6  is sealed so that the internal space within the elevation structure  6  is not penetrable by water or other liquids. In some embodiments, the elevation structure  6  may be of a fixed height with an item stored internally upon manufacture. For example, a survival item such as matches, first aid materials, or flint and steel may be sealed into the elevation structure  6  during manufacture. These materials could be accessed by removing the elevation structure  6  from the insert  1  or only a portion of the elevation structure  6 . 
         [0029]      FIG. 1G  illustrates an alternate embodiment of the elevation structure  6  with a central screw track situated within a portion of the elevation structure fixed to the slats  2  of the insert. In the illustrated embodiment, the user twists the region  8  of the elevation structure  6 . Other embodiments may incorporate other arrangements for fixed or adjustable elevation structures  6 . 
         [0030]      FIG. 2  depicts a schematic diagram of another embodiment of a chest cooler insert with offset drainage structure openings. The illustrated embodiment includes an upper plate  10  and a lower plate  11 . The upper plate  5  includes an upper drainage structure pattern  12 . The lower plate  11  includes a lower drainage structure pattern  13 . In the illustrated embodiment, the upper drainage structure pattern  12  is offset from the lower drainage structure pattern  13 . This facilitates drainage of water or other material through the upper and lower plates  10  and  11  but increases the resistance to water or other material splashing or sloshing back up through the lower and upper plates  10  and  11 . 
         [0031]      FIG. 3  depicts a schematic diagram of one embodiment of a chest cooler with a cutaway showing the insert of  FIG. 1 . In the illustrated embodiment, the insert  1  is placed in the bottom of the cooler  20 . In some embodiments, the insert  1  is removable to provide greater ease in washing and using the insert in multiple applications. In another embodiment, the insert  1  is permanently installed into the bottom of the cooler  20 . For example, the insert  1  may be put in place during manufacture of the cooler  20  or inserted after the cooler  20  is formed. In some embodiments, the insert  1  includes suction cups or flanges to attach to the internal sides of the cooler  20 . Other manners of securing the insert  1  within the cooler  20  may be implemented. 
         [0032]      FIGS. 4A and 4B  depict schematic diagram views of another embodiment of a chest cooler insert  100  with drainage structure openings. The illustrated embodiment includes a base  102  with surface channels  103  and drainage structures  104 . In some embodiments, the base  102  is constructed of a plastic. In other embodiments, the base  102  is constructed of a composite. Other materials may be used without deviating from the scope of the invention. In the illustrated embodiment, the base includes the channels  103 . In one embodiment, the channels  103  allow water or other material to flow away from the surface of the insert  100  and into the drainage structures  104 . In the illustrated embodiment, the drainage structures  104  are an x-pattern perforation passing completely through the base  102  to allow material to drain through the insert  100 . In some embodiments, the drainage structures  104  are circular holes. In other embodiments, the drainage structures  104  are parallel or non-parallel linear slots through the thickness of the base  102 . Other embodiments may incorporate other arrangements, patterns, geometries, or sizes of drainage structures  104 . In some embodiments, the insert  100  includes a grip point  106 . The grip point  106  provides a location on the insert  100  where a user may grip the insert  100  for placing the insert  100  within a cooler or removing the insert  100  from a cooler. In other embodiments, multiple grip points  106  may be included. 
         [0033]    In some embodiments, the insert  100  is size adjustable. As described above, the adjustment may be permanent or temporary. In some embodiments, the adjustment includes permanently removing a portion of the insert  100  to accommodate use within a particular size cooler. Other embodiments may include adjustable elements to expand and reduce the size of the insert  100  to accommodate different sizes of coolers. In some embodiments, the insert  100  may maintain a separation from the interior walls of the cooler of approximately 0.5 inches. In some embodiments, the insert  100  includes a flexible flange around the perimeter of the insert  100  to provide a seal and secure the insert  100  within the cooler. 
         [0034]    The illustrated embodiment of the insert  100  also includes elevation structures  6  shown in  FIG. 4B . The illustrated elevation structures  6  are similar to those described above with reference to  FIGS. 1F and 1G . In some embodiments, the elevation structures  6  are suction cups oriented to attach to the sides or bottom surface of a cooler. In another embodiment, the elevation structure  6  include flanges to engage with grooves along the inside surface of a cooler. Other structures may be used to elevate the insert  100  above the bottom surface of a cooler or other surface. 
         [0035]      FIGS. 5 and 6  depict another embodiment of a chest cooler insert  500  with size adjustment features. The illustrated embodiment includes an upper base  502  with surface channels  503  and drainage structures  504 . Each surface channel  503  may be separated from the adjacent channel  503  by a ridge  505 , the ridges and channels may be formed through the entire upper base  502 , giving it a regularly undulating cross-sectional shape in the depicted embodiment. 
         [0036]    As depicted, at a first end  501 , the upper base  502  may have a handle portion  506  formed as an inset to allow a user to place their hand therein when the base is adjacent a cooler interior wall, and have a downwardly extending outer rim or wall, which extends around a corner to join a downwardly extending longitudinal sidewall  508  along a first longitudinal side of the base  502 . The opposite second end  507  may lack such a wall. Along the second longitudinal side of the base  502 , a downwardly extending longitudinal sidewall  509  similarly joins the downwardly extending wall or rim on the first end  501 . As best depicted in  FIG. 7 , a series of connection notches  520  may be formed in the sidewall  509  at the top corner thereof in the upper surface of the base  502 . 
         [0037]    An upper expansion member  510  may be joined to the upper base  502  by placement of the counterpart connection tabs  512  into to the connection notches  520 . In the depicted embodiment, the upper expansion member  510  has an upper surface with at least one surface channel  513  containing drainage structures  504 , to form a continuous surface with the upper surface of the upper base  502  upon joining. A downwardly extending longitudinal sidewall  514  may abut the longitudinal sidewall  509  of the upper base member  502  as best depicted in  FIG. 6  to form an elongated tab. 
         [0038]    The illustrated embodiment also includes a lower base  552  with surface channels  553  and drainage structures  554 . Each surface channel  553  may be separated from the adjacent channel  553  by a ridge  503 , the ridges and channels may be formed through the entire upper base  552 , giving it a regularly undulating cross-sectional shape in the depicted embodiment. 
         [0039]    As depicted, at a first end  551 , the lower base  552  may have a handle portion  556  formed as an inset to allow a user to place their hand therein when the base is adjacent a cooler interior wall, and have a downwardly extending outer rim or wall, which extends around a corner to join a downwardly extending longitudinal sidewall  558  along a first longitudinal side of the base  552 . Along the second longitudinal side of the base  552 , a downwardly extending longitudinal sidewall  561  similarly joins the downwardly extending wall or rim on the first end  551 . As best depicted in  FIG. 8 , a series of connection notches  570  may be formed in the sidewall  561  at the top corner thereof in the upper surface of the base  552 . 
         [0040]    A lower expansion member  560  may be joined to the lower base  552  by placement of the counterpart connection tabs  562  into to the connection notches  570 . In the depicted embodiment, the upper expansion member  560  has an upper surface with at least one surface channel  563  containing drainage structures  504 , similar to the upper surface of the lower base  552  that will be generally coplanar thereto upon joining. A downwardly extending longitudinal sidewall  565  extends along one side of the lower expansion member  560  and a planar member  567  extends generally orthogonally therefrom. The connection tabs  562  may be disposed on the opposite side of the planar member  567 . Upon installation to the lower base  552 , the longitudinal sidewall  565  faces the longitudinal sidewall  509  of the lower base member  552  to form a channel with the planar member  567  forming the “floor” thereof. 
         [0041]    The matching patterns of the channels and ridges of the upper and lower base members  502  and  552  and the upper and lower expansion members  510  and  560  allow for a close fit therebetween. Where the expansion members are attached, the parallel longitudinal sidewalls  509  and  514  of the upper base  502  and upper expansion member  510  reside in the channel formed between the sidewalls  565  and  509  of the lower expansion member  560  and the lower base  552 , as best depicted in  FIG. 6 . 
         [0042]    The relative position of the upper and lower bases  502  and  552  may be telescopically adjusted with respect to one another by sliding movement. This allows the insert  50  to be adjusted in a longitudinal direction to fit in the interior space of coolers of different sizes. Similarly, the ability to connect and disconnect the upper and lower expansion members  510  and  560  to the bases allows for the insert  50  to be adjusted in a latitudinal direction for placement in coolers of different sizes. The ability of the expansion members  510  and  560  to be slidably adjusted with respect to one another as the abutting sidewalls  509  and  514  reside in the channel allows for adjustment in both directions separately. It will be further appreciated that in some embodiments, both longitudinal edges of the bases  502  and  552  may be configured for and joined to expansion members. 
         [0043]    In some embodiments, the bases  502  and  552  may be constructed of a plastic. In other embodiments, the bases  502  and  552  may be constructed of a composite. Other materials may be used without deviating from the scope of the invention. In the illustrated embodiment, the bases includes the channels  503  and  513 , which allow water or other material to flow away from the surface of the insert  50  and into the drainage structures  504 . In the illustrated embodiment, the drainage structures  504  are an x-pattern perforation passing completely through the base  502  or  552  to allow material to drain through the insert  50 . In some embodiments, the drainage structures  504  are circular holes. In other embodiments, the drainage structures  504  are parallel or non-parallel linear slots. Other embodiments may incorporate other arrangements, patterns, geometries, or sizes of drainage structures  504 . In some embodiments, the insert  50  may include a medallion M formed as an area to bear a logo or other identifying matter. 
         [0044]    It will be appreciated that the shapes of the depicted connection tabs  512  and  562  and corresponding connection notches  520  and  570  are illustrative and that any suitably shaped structures may be used. 
         [0045]    In some embodiments, the insert  50  may include a flexible flange around the perimeter of the insert  50  to provide a seal and secure the insert  100  within a cooler. 
         [0046]    The illustrated embodiment of the insert  50  also includes elevation structures shown in  FIG. 9 . The illustrated elevation structures a number of brackets  900  disposed on the lower surfaces of the bases  502  and  552 . In the depicted embodiment, the bracket  900  is formed as a protuberance containing two slots that form an x-shape. A leg member  902  having an x-shaped cross-section can be inserted into the bracket to form a leg holding the insert  50  above the floor of the cooler. It will be appreciated that other elevation structures, such as ones similar to those described above with reference to  FIGS. 1F and 1G  may be used. In other embodiments, the elevation structures could be suction cups oriented to attach to the sides or bottom surface of a cooler, flanges to engage with grooves along the inside surface of a cooler, or other structures that may be used to elevate the insert  50  above the bottom surface of a cooler or other surface. In other embodiments, the elevation structures could be recesses or portions of the insert  50  that receive support from structures formed on an interior surface of a cooler, such as protrusions or a ridge formed thereon for holding shelves or dividers. It will be appreciated that different numbers and patterns of elevation structures, including brackets  900  and legs  902  or other structures may be used, depending on the size and strength of the insert  50 . 
         [0047]    While this disclosure has been described in certain embodiments, the present invention can be further modified with the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practices in the art to which this invention pertains and which fall within the limits of the appended claims.