Patent Publication Number: US-2012037643-A1

Title: Cooler with tray

Description:
FIELD OF THE INVENTION 
     The inventions described below relate to the field of a portable cooler, and, more particularly, to such a cooler having a rotatably mounted tray attached onto the cooler&#39;s side portion. 
     BACKGROUND OF THE INVENTION 
     Portable coolers (also known as ice chests, coolers, etc.) are a common consumer product. Portable, insulated containers are commonly used when electrical or gas powered refrigeration, or warming means, are not convenient or available, for example, in remote locations such as the beach, parks, boating, and the like. They are used to maintain food and beverages at a desired temperature, usually, but not always, colder than room temperature. 
     It is often desirable to have a table or other work surface upon which to position food or utensils. Many coolers have flat upper surfaces on their lids or covers that may be used as a table surface. However, when the lid or cover is being used as a table surface, it is impossible to achieve access to the interior of the cooler without first taking all objects off of the lid of the cooler. 
     While there are numerous coolers with table assemblies designed for transport and accessibility of items within the container, many of these designs found in prior art make no attempt to provide an insulated storage container with an attached, deployable table that is engineered to work with both small and large sized coolers, leaves a small footprint, is quickly and easily deployable, is simple to manufacture, adds relatively little weight to the container, contributes no additional bulk to the container&#39;s exterior profile, and, while in a position of use, allows the user to fully access the interior of the container. 
     Various coolers contain a tray element that is used as a table surface. Kaplan,  Combination portable cooler and retractable tray,  U.S. Pat. No. 7,334,802 (Jun. 29, 2005) describes a portable cooler with a double “pop top” lid component that allows the user to raise and lock into an adjustably deployed position an upper lid to be used as a table surface directly above the cooler while a lower lid remains in the stowed position keeping the cooler closed. This invention succeeds in providing a table surface while allowing access to the container, but is not engineered for optimum use with smaller-sized coolers due to the top-heavy nature of the upward extending upper tray portion; fails to be simply and quickly deployable; fails to be simple to manufacture; its various embodiments each add significant weight to the container; each of the various embodiments include support components affixed to the container&#39;s exterior composition, adding bulk to the exterior of the container; and, finally, none of the embodiments allow the lid to fully open while the tray is in its deployed position. 
     Another such cooler with a table surface is described in Conrado, et al.,  Wheeled cooler,  U.S. Pat. No. 6,328,179 (Jul. 14, 2000), whereby a tray element containing a leg support component therein is attached to the cooler&#39;s lid with a hinge element that allows said tray to swing 180 degrees into a deployed position, creating a flat table surface adjacent to the cooler body. This invention succeeds in providing a table surface while allowing access to the container, and allows the lid to be fully open while the tray is in its deployed position. However, the embodiment described in this invention adds extra bulk to the lid portion of the cooler, resulting in significant additional weight; a work space proportionate to the horizontal length of the cooler is needed in order for the fold-over lid to be deployed, requiring a large work space, resulting in an overall large footprint; when the tray is in its deployed position and the user opens the cooler cover, said cover rotates over on top of the deployed tray due to the common pivot axis of the first and second hinges of the respective cover and tray, resulting in the contents resting atop the table surface to get displaced or damaged; and, finally, the embodiment described in this invention is not engineered for optimum use with smaller-sized coolers due to the increased weight of the lid and table assembly. 
     Furthermore, as seen in Meier,  Portable cooler having a removable table,  U.S. Pat. No. 5,947,032 (Sep. 14, 1998), a cooler invention is described as containing a removable tray embedded within a hollow cavity within the cooler lid. Said tray is provided with folding legs at one end, and the other tray end is configured to be matingly received and supported by either one of two handles of the cooler. This invention succeeds in providing a table surface while allowing access to the container, and allows the lid to be fully open while the tray is in its deployed position, and adds no additional bulk to the exterior profile of the cooler by way of embedding the tray within a hollow cavity of the cooler lid, but problems often arise with the stability of the table, and a detached tray/lid may become misplaced or lost, potentially rendering the assembly inoperable; and, finally, the embodiment described in this invention clearly fails to provide the user a quickly deployable, attached table assembly. 
     The invention described below comprises an insulated storage container with a rotatably mounted, deployable table that is embedded within the side portion of the container. Said table is quickly and easily deployable, engineered to work with both small and large size containers, leaves a small footprint, is simple to manufacture, adds relatively little weight to the container, contributes no additional bulk to the container&#39;s exterior composition, and, while in a position of use, allows the user to fully access the interior of the container. 
     SUMMARY OF THE INVENTION 
     It is the principal object of the invention to provide a new and improved portable cooler. 
     According to one facet of the invention, a cooler is provided that includes a typical double-walled cooler body consisting of an interior cavity and exterior shell comprised of insulating material. Said double-walled cooler body consists of forward and rear walls, end walls, and a bottom panel. An upper access opening is provided for receipt of items whose temperature is to be maintained at a predetermined level. A cover member is provided for the access. A tray cavity portion that includes a thumb notch and female sockets along its upper edge is provided on the shell portion of the forward wall. A tray element that includes a lower tray surface and male rotatable joint mechanisms along its upper edge is provided. A pair of leg cavity portions that include female sockets and leg thumb notches are contained on said lower tray surface. Two tray legs that include male rotatable joint mechanisms are provided. The legs have a length generally the same as the height of the body. 
     Consequently, the tray element nests within the tray cavity during transportation of the cooler and yet may be opened with the legs deployed to provide a table surface adjacent to the cooler body. The use of the separate tray surface enables one to use the tray surface and yet achieve access to the interior of the cooler body by opening the cover without first clearing the tray surface. 
     In a preferred embodiment, the leg cavities are positioned on the lower tray surface at an angle to gain additional leg length, making up for the lost distance between the lower edge of the forward wall and lower edge of the tray cavity. 
     A preferred embodiment includes stops on the tray cavity socket elements for engaging the tray joint elements to limit movement of the tray from a stowed position nested within the tray cavity to a deployed position approximately 90 degrees therefrom. 
     A preferred embodiment includes stops on the leg cavity socket elements for engaging the leg joint elements to limit movement of the legs from a stowed position nested within the leg cavities to a deployed position approximately 90 degrees therefrom. 
     A preferred embodiment includes an impeding element on the leg cavity portion for the purpose of engaging the legs while in the deployed position approximately 90 degrees from the tray element in order to keep the legs upright while the tray element is deployed, but is conveniently overcome by forcing the legs over the impeding element and releasing said legs from their deployed position. 
     A preferred embodiment includes an impeding element on the tray cavity portion for the purpose of engaging the tray in order to keep the tray nested within the tray cavity while in a stowed position during transport, but is conveniently overcome by forcibly lifting the tray over the impeding element and deploying said tray from its stowed position. 
     A preferred embodiment includes a thumb notch on the forward wall portion adjacent to the tray cavity for the purpose of conveniently grasping hold of the tray element and releasing it from a stowed position. 
     A preferred embodiment includes a thumb notch on the lower surface area of the tray element adjacent to each leg cavity for the purpose of conveniently grasping hold of the leg element and releasing it from a stowed position. 
     In one embodiment, a tray element is provided on the end wall portion. 
     In yet another embodiment, a tray element is provided on both exterior shell forward wall and rear wall portions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary embodiment of a portable cooler made according to the invention; 
         FIG. 2  is a perspective view of the cooler with its tray member extended and leg elements in a stowed position; 
         FIG. 3  is a is a perspective view of the cooler with its tray member extended and leg elements in a deployed position; 
         FIG. 4  is a perspective view of the cooler with the cover member removed and tray member and leg elements in a deployed position; 
         FIG. 5  is a vertical sectional view of the cooler with its tray member extended and leg elements in a deployed position; 
         FIG. 6  is a front view of the forward facing wall portion with the tray member in its stowed position nested within the tray cavity; 
         FIG. 7  is a front view of the forward facing wall portion with the tray member removed and tray cavity exposed; 
         FIG. 8  is a birds-eye view of the lower tray surface with the leg elements in their stowed position nested within the leg cavity portions; 
         FIG. 9  is a birds-eye view of the lower tray surface with the leg elements removed and leg cavity portions exposed; 
         FIG. 10  is a vertical view illustrating an alternative configuration of tray members contained on each side of the cooler; and 
         FIG. 11  is a perspective view illustrating an alternative configuration of a cooler with the tray member residing on an end wall. 
       The invention and its various embodiments can now be better understood by turning to the following description of the preferred embodiments which are presented as illustrated examples of the invention in any subsequent claims in any application claiming priority to this application. It is expressly understood that the invention as defined by such claims may be broader than the illustrated embodiments described below. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to the figures wherein like references define like elements among the several views,  FIG. 1  shows the exemplary embodiment of the Portable Cooler  1 . Said cooler includes a typical double-walled cooler body consisting of an interior cavity and exterior shell comprised of insulating material. Said embodiment includes four principal components including a Body  24 , a Cover Member  5 , a Tray  8  which is embedded in and pivoted to the Body  24  by means to be seen, and Legs  10  which are embedded in and pivoted to the Tray  8  by means to be seen. 
     Addressing the Body  24 , and as seen in  FIG. 1 , the same includes a Forward Wall  2 , opposed End Walls  25 ,  26 , a Rear Wall  3 , and a Bottom Panel  4 . A Tray Cavity  9  is embedded on the shell of Forward Wall  2  by means to be seen for the purpose of nesting a Tray  8 . Body  24  is generally rectangular in shape. Briefly referring to  FIG. 4 , Upper Access Opening  6  gives way to Internal Container Cavity  7 . 
     Again referring to  FIG. 1  and addressing the Cover Member  5 , the same, for example, is a removable lid for the purpose of achieving accesses to the container&#39;s interior while in its deployed position, and, keeping the contents therein at a desirable temperature while in its stowed position. It is common in the field of coolers for the lid to attach to the body by way of a rotatably mounted hinge mechanism whereby the lid can be opened and closed while remaining permanently attached to the body. For descriptive purposes of the present invention, the cooler is described as having a removable lid. 
     Briefly referring to  FIG. 5 , the Body  24  and Cover Member  5  are made up of Insulating Material  27  as is well known. Conventionally, Body  24  will include an inner shell (not shown), an outer shell, and foam forming the Insulating Material  27 . 
     Again referring to  FIG. 1  and addressing the Tray  8 , which is located on Forward Wall  2  of Body  24 . Tray  8  nests inside Tray Cavity  9  of Forward Wall  2 . Said Tray Cavity  9  is formed in the same configuration as the Tray  8  to substantially fully receive the Tray  8  in the retracted or stowed position, as illustrated in  FIG. 1 . If desired, suitable detents (not shown) may be employed to releasably retain the Tray  8  within the Tray Cavity  9 . When Tray  8  is in its stowed position, it is in abutment with Tray Cavity  9 , resulting in a flat surface area along Forward Wall  2  of Body  24 . 
     Now referring to  FIG. 6 , located at either end of the Tray Upper Edge  18  of Tray  8  is a pair of Tray Joints  13 . Tray Joint End Points  35  are located at opposing ends of said Tray Joints  13 . Furthermore, a pair of Tray Flex Notches  29  are located between Tray Joint End points  35  along the upper edge of said Tray Joints  13 . 
     Turning to  FIG. 7 , the Tray Cavity Sockets  14  of Tray Cavity  9 , located along Upper Tray Cavity Edge  19 , are provided for the purpose of receiving Tray Joints  13 . Located at opposing ends of the Tray Cavity Sockets  14  are Tray Cavity Socket Overlapping Portions  33  for the purpose of retaining Tray Joint End Points  31 . 
     Tray Joint End Points  31  are forcibly constrained toward each other by way of the Tray Flex Notches  29 , allowing said Tray Joint End Points  31  to be fitted into their stowed position underneath Tray Cavity Socket Overlapping Portions  33  of Tray Cavity Sockets  14 , as shown in  FIGS. 1 and 6 . 
     Referring again to  FIG. 6 , once Tray Joints  13  are stowed within Tray Cavity Sockets  14 , Tray Cavity Socket Overlapping Portions  33  retain Tray Joint End Points  31  keeping Tray Joints  13  contained within Tray Cavity Sockets  14 , thereby attaching Tray  8  to Tray Cavity  9  of Forward Wall  2  of Body  24 . 
     Tray Joints  13  pivot within Tray Cavity Sockets  14  approximately 90 degrees, resulting in Tray  8  extending outward from Forward Wall  2  into a deployed position, as illustrated in  FIGS. 2 ,  3 ,  4  and  5 , providing a Flat Table Surface  28  adjacent to said Forward Wall  2 . 
     Again referring to  FIG. 7 , a Tray Cavity Thumb Notch  21  is provided on Forward Wall  2  adjacent to Tray Cavity  9  for the purpose of conveniently grasping hold of Tray  8  and releasing it from a stowed position. 
     Turning now to  FIG. 8  and addressing the pair of Legs  10 , which are located on Lower Tray Surface  12  of Tray  8 . Legs  10  nest inside Leg Cavity  11  of Tray  8 . Said Leg Cavity  11  is formed in the same configuration as the Legs  10  to substantially fully receive the Legs  10  in the retracted or stowed position as illustrated in  FIG. 8 . If desired, suitable detents (not shown) may be employed to releasably retain the Legs  10  within the Leg Cavity  11 . When Legs  10  are in their stowed position, they are in abutment with Leg Cavity  11 , resulting in a flat surface area along Lower Tray Surface  12  of Tray  8 . 
     Again referring to  FIG. 8 , a pair of Leg Joints  15  are located on Legs  10 . Leg Joint End Points  32  are located at opposing ends of said Leg Joints  15 . Furthermore, a pair of Leg Flex Notches  30  are located between Leg Joint End Points  32  of Legs  10 . 
     Briefly turning to  FIG. 9 , located on Leg Cavity  11  of Lower Tray Surface  12  of Tray  8  is a pair of Leg Cavity Sockets  16  for the purpose of receiving Leg Joints  15 . Located at opposing ends of Leg Cavity Sockets  16  are Leg Cavity Socket Overlapping Portions  34  for the purpose of retaining Leg Joint End Points  32 . 
     Leg Joint End Points  32  are forcibly constrained toward each other by way of the Leg Flex Notches  30 , allowing said Leg Joint End Points  32  to be fitted into their stowed position underneath Leg Cavity Socket Overlapping Portions  34  of Leg Cavity Sockets  16 , as shown in  FIG. 8 . 
     Again referring to  FIG. 8 , once Leg Joints  15  are stowed within Leg Cavity Sockets  16 , Leg Cavity Socket Overlapping Portions  34  retain Leg Joint End Points  32  keeping Leg Joints  15  contained within Leg Cavity Sockets  16 , thereby attaching Legs  10  to Leg Cavity  11  of Lower Tray Surface  12  of Tray  8 . 
     Leg Joints  15  pivot within Leg Cavity Sockets  16  approximately 90 degrees, resulting in Legs  10  extending outward from Tray  8  into a deployed position, and serve as vertical braces for said Tray  8 , as illustrated in  FIGS. 3 ,  4 , and  5 . 
     Referring to  FIG. 3 , it is to be noted that the vertical length of the Legs  10  are substantially the same as the vertical distance between the Forward Wall Lower Edge  17  of the Body  24  and the Tray Cavity Upper Edge  19  so that when the Legs  10  are deployed, Tray Surface  28  will be flat and said Tray Surface  28  will be perpendicular to Forward Wall  2  at a generally 90-degree angle thereto. 
     Again referring to  FIG. 3 , Lost Distance  23  is the surface area between Forward Wall Lower Edge  17  of the Body  24  and Tray Cavity Lower Edge  20 . Briefly referring to  FIG. 8 , it is noted that Legs  10  and Leg Cavities  11  are set at an angle. The purpose of the angularly positioned Legs  10  and Leg Cavities  11  is to gain additional leg length to compensate for Lost Distance  23 , thereby enabling Tray Surface  28  to rest in its deployed position perpendicular to Forward Wall  2 . 
     Referring once again to  FIG. 9 , a pair of Leg Cavity Thumb Notches  22  is provided on Lower Tray Surface  12  adjacent to Leg Cavity  11  for the purpose of conveniently grasping hold of Legs  10  and releasing them from a stowed position. 
     Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by any claims in any subsequent application claiming priority to this application. 
     For example, notwithstanding the fact that the elements of such a claim may be set forth in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. 
     The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus, if an element can be understood in the context of this specification as including more than one meaning, then its use in a subsequent claim must be understood as being generic to all possible meanings supported by the specification and by the word itself. 
     The definitions of the words or elements of any claims in any subsequent application claiming priority to this application should be, therefore, defined to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense, it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in such claims below or that a single element may be substituted for two or more elements in such a claim. 
     Although elements may be described above as acting in certain combinations and even subsequently claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that such claimed combination may be directed to a subcombination or variation of a subcombination. 
     Insubstantial changes from any subsequently claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of such claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. 
     Any claims in any subsequent application claiming priority to this application are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.