Patent Publication Number: US-8967419-B2

Title: Portable cooler device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. provisional application No. 61/676,743, filed Jul. 27, 2012, the contents of which are herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to coolers and, more particularly, to coolers that have the ability to keep objects in useable or consumable condition after leaving their primary refrigerated storage location. 
     Currently, coolers are not efficient at providing cooling for a long period of time. It is necessary to keep the thermal insulation, cooling source and storage compartment separated and arranged in a specific manner for it to be efficient for extended periods of time. A typical cooler will not keep the storage compartment under 60 degrees Fahrenheit, at 85 degrees Fahrenheit test temperature, for more than approximately one hour. One hour is not a significant amount of time for items that need to be kept cool for an extended period of time. Other coolers are commonly just a single piece expanded polystyrene container surrounded by an exterior shell. These coolers do not have the desired arrangement of components because there is no thermally conductive path between a cooling source and the storage compartment, providing little to no benefit. 
     As can be seen, there is a need for a device that may keep objects in useable or consumable condition after leaving their primary refrigerated storage location for significant amounts of time. 
     SUMMARY OF THE INVENTION 
     In one aspect of the present invention, a portable cooler device comprises an exterior shell; an insulated container having at least one hole and a top outer edge, wherein the insulated container is surrounded by the exterior shell; at least one cooling insert having an interior housing, wherein the at least one cooling insert is held by the insulated container; a liner having a top side and an internal portion that defines a cooling chamber, wherein the liner surrounds an outer surface of the interior housing of the at least one cooling insert; a cover having a bottom portion and a top portion, wherein the cover is connected to the liner and covers the cooling chamber; and a carrying handle that holds the cover in place and secured by fasteners to at least one hole in the insulated container. 
     In another aspect of the present invention, a portable cooler device comprises an exterior shell; an insulated container having a latch receiver, at least one hole and a top outer edge, wherein the insulated container is surrounded by the exterior shell; at least one cooling insert having an interior housing, wherein the at least one cooling insert is held by the insulated container; a liner having a top side and an internal portion that defines a cooling chamber, wherein the liner surrounds an outer surface of the interior housing of the at least one cooling insert; a cover having a bottom portion, a top portion and a cover latch, wherein the cover is connected to the liner and covers the cooling chamber; and a carrying handle that holds the cover in place and secured by fasteners to the at least one hole in the insulated container. 
     In yet another aspect of the present invention, a method of creating a portable cooler device comprises providing an exterior shell; providing an insulated container having at least one hole and a top outer edge, wherein the insulated container is surrounded by the exterior shell; providing at least one cooling insert having an interior housing; freezing the at least one cooling insert; placing the frozen at least one cooling insert into the insulated container; providing a liner having a top side and an internal portion comprising cooling chamber; placing the liner within the interior housing of the at least one cooling insert; providing a cover having a bottom portion and a top portion, wherein the cover is connected to the liner and covers the cooling chamber; and providing a carrying handle that holds the cover in place and is secured by fasteners to at least one hole in the insulated container. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary embodiment of the present invention; 
         FIG. 2  is an exploded view of an exemplary embodiment of the present invention; 
         FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 1 ; and 
         FIG. 4  is an exploded view of an alternate embodiment of the present invention. 
         FIGS. 5A-D  illustrate graphically the results of cooling capacity studies of the present invention. The factors of the study were; insulated container thickness, liner thickness, and grams of cooling insert. 
         FIG. 6  is the transfer function for time, based on cooling capacity study components of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. 
     Broadly, an embodiment of the present invention provides a portable cooler device. The portable cooler device may include an exterior shell, an insulated container surrounded by the exterior shell and at least one cooling insert held by the insulated container. A liner that may have a cooling chamber may surround an outer surface of the interior housing of the at least one cooling insert. A cover may be included so that the contents of the cooling chamber may stay cool. A carrying handle may hold the cover in place and allow for transport. 
     Referring now to  FIGS. 1 through 6 , a portable cooler device  10  may include an exterior shell  14 . The exterior shell  14  may surround an insulated container  16 . The insulated container  16  may hold at least one cooling insert  30 . The at least one cooling insert  30  may have an interior housing. A liner  28  may surround an outer surface of the interior housing of the at least one cooling insert  30 . The internal portion of the liner  28  may define a cooling chamber  32 . Closing the top of the device may be a cover  18  which may also include a handle  20 . In order to hold the device, a carrying handle  12  may be connected to the cover  18  and the insulated container  16 . The carrying handle  12  may run through a hole  22  in the cover  18  and at least one hole  26  in the insulated container  16 . At least one fastener  24  may be used to keep the carrying handle  12  secure. 
     In certain embodiments as shown in  FIG. 4 , the device  10  may include a cover latch  34  attached to the cover  18 . The cover latch  34  may be secured through a latch receiver  36  positioned along the insulated container  16 . The carrying handle  12  may have at least one attachment pin  38  that may enter the at least one hole  26  in the insulated container, and at least one hole  26  in the exterior shell  14 . 
     The exterior shell  14  may house the insulated container  16 . The exterior shell  14  may provide protection from wear and tear, as well as provide space for advertising and instruction purposes along the outside portion of the exterior shell  14 . Placed inside of the exterior shell  14  may be the insulated container  16 . The insulated container  16  has a top outer edge. The insulated container  16  may provide a rigid exterior for the device  10  and also may provide insulation between the exterior of the device  10  and the at least one cooling insert  30 . The insulated container  16  may have at least one extended portion  42  that may provide an extended lip for the top outer edge of the insulated container  16  and may have at least one hole  26  in the insulated container. 
     The at least one cooling insert  30  may effectively keep the contents of the cooling chamber  32  cool and fresh longer than ice, without the watery mess. The at least one cooling insert may be made from a polymer gel formation or gel pack and the like. The at least one cooling insert  30  also may provide thermodynamic heat transfer that enables cooling the inside of the cooling chamber  32  lower than 60 degrees Fahrenheit for up to eight hours with an outside temperature of 85 degrees Fahrenheit. The at least one cooling insert  30  may have an interior housing. The liner  28  may be positioned so that the liner  28  surrounds an outer surface of the interior housing of the at least one cooling insert  30 . The liner  28  may separate the at least one cooling insert  30  from the contents within the cooling chamber  32 . The liner  28  may control the heat transfer process between the contents of the cooling chamber  32  and the at least one cooling insert  30 . The liner  28  may be removable so that the liner  28  may be easily cleaned. In certain embodiments, the liner  28  also may include a cutting surface  40  so that in certain instances, such as fishing and the like, preparation may be carried on in order for the bait to be ready to being placed on a line. The cutting surface  40  may be along the top side of the liner  28 . As is mentioned above, the contents of the present device  10  may be within the cooling chamber  32 . 
     In order to keep the temperature low within the cooling chamber  32 , a cover  18  may be used. The cover  18  may enclose any open faced portions of the present device  10 . The cover  18  provides an insulated cover to help keep the cooling chamber  32  cool. The cover  18  keeps the contents of the cooling chamber  32  within the cooling chamber  32 . Along the bottom portion of the cover  18  may be lid flange that may allow the cover  18  to maintain a concentric fit between the cover  18  and the liner  28 . Along the outside portion of the cover  18  may be an external shell that may provide abrasion protection along with the required thermal properties. The cover  18  may be held in place by the carrying handle  12 . The carrying handle  12  may be used to transport the present device  10 . The cover  18  may be connected to the insulated container  16  by the carrying handle  12  in certain embodiments, or by the cover  18  alone in other embodiments. The carrying handle  12  may connect through a hole in the cover  22  and at least one hole  26  in the insulated container that may be located on at least one extended portion  42  that may provide an extended lip for the top outer edge of the insulated container  16 . The cover  18  may be easily removed from the rest of the present device by a centrally located handle  20 . At least one fastener  24  may be positioned below the at least one hole  26  in the insulated container so that the carrying handle  12  may be secured in place. 
     A method of using a portable cooler device may include the following. Place the at least one cooling insert into a freezer until it is completely frozen. The polymer gel formation may freeze at a temperature set within a freezer. Once the at least one cooling insert is frozen, place it inside of the insulated container. Place the liner inside of the at least one cooling insert and the position any object that needs to be cooled inside of the cooling chamber. Once the object or objects are positioned within the cooling chamber, cover the present device with the cover. The present device may be used to store items that may need to be cooled for an extended time without power, which may include objects such as edible items, medication and the like. The size of the portable cooler may be adjusted as long as the present device still maintains effective cooling for objects. The insulated container may be made from Styrofoam and the like. 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.