Patent Abstract:
The present invention is a unitary cooling apparatus capable of standard freezing time despite heavy insulation. One embodiment of the apparatus includes a zipper component which extends along the edges of a top surface and bottom surface allowing the top and bottom to be pivoted outward or inward and the cooling apparatus flattened along the seams which connect the sides. A plurality of cube structures positioned along a plurality of channels allows rapid cooling using a minimum of frozen fluid.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part application that claims priority to U.S. application Ser. No. 11/110,179 filed on Apr. 20, 2005. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to the field coolers and more specifically to a cooler with integrally constructed freezing and insulating components which can be flattened to less than three inches to be stored in a freezer in a flattened position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  illustrates an exemplary embodiment of a plurality of single component flat cooling apparatuses in a flattened position and stacked in a residential-size freezer: 
           [0004]      FIG. 2  illustrates an exemplary embodiment of a single component flat cooling apparatus in the non-flattened position. 
           [0005]      FIG. 3  illustrates an exemplary embodiment of a single component flat panel cooling apparatus which has a pivotal top and pivotal bottom capable of being pivoted to a substantially flush position against a unitary freezing panel in a flattened position. 
           [0006]      FIG. 4  illustrates the range of motion of pivotal top and pivotal bottom components capable of operating as the top and bottom of a structure and secured with a zipper component or moved to flush position against a unitary freezing panel in a flattened position. 
           [0007]      FIG. 5  illustrates a side perspective view of an exemplary embodiment of a single component flat cooling apparatus in a flattened position for space-efficient storage within a freezer. 
           [0008]      FIG. 6  illustrates a cross-sectional view of a integrally constructed insulating and freezing layers of single component flat cooling apparatus. 
       
    
    
     GLOSSARY 
       [0009]    As used herein, the term “fluid” refers to a substance used for cooling (creating ice or other frozen component). Examples of fluid include water, water with additives, a gel solution (e.g., hydroxyethyl cellulose (Cellusize™), vinyl-coated silica gel) or another substance or solution capable of providing a chilling effect on surrounding materials by absorbing heat. 
         [0010]    As used herein, the term “unitary freezing panel” means a component of a cooling apparatus made up of a plurality of layers, including, but not limited to, freezing, reflective and/or insulating layers. For example a flat panel may be comprised of multiple freezing and insulation layers, including but not limited to a fabric layer, an insulation layer, an inner reflective layer, a multi-channeled fluid layer and a polyethylene layer. 
         [0011]    As used herein, the term “multi-channeled” means having openings, lanes, spacing, etc. (horizontal or vertical) between structural components (e.g., freezing cubes, bubbles and/or pockets). Channels may be created by sewing, heat sealing, stamping, molding, machining and combinations thereof. 
         [0012]    As used herein, the term “standard freezing time” refers to a freezing process which occurs during a measurable time frame, e.g., the normal time frame for freezing of water. 
         [0013]    As used herein, the term “panel insertion channel” is a portion of a cooler which allows a component of a machine used for embellishment to be more easily used. For example, a panel insertion channel may be an extra panel of fabric attached to one or more unitary freezing panels of the cooling apparatus which allows for insertion of a component of an embroidery or silk screening machine. 
         [0014]    As used herein, the term “anti-freeze fiber additive” means an additive added to fibers of a layer, such as a fabric layer, insulation layer, reflective layer, fluid layer or any other layer, that makes it resistant to cracking when frozen. For example, an anti-freeze material may be added to fibers during the manufacturing process. 
         [0015]    As used herein, the term “weight resistant zipper” means a fastener that temporarily joins two edges of fabric and is capable of withstanding a substantial amount of weight. For example, a weight resistant zipper may be capable of joining two edges of fabric under 200 pounds of weight. 
         [0016]    As used herein, the term “notched seam” means a component which creates a seam by notching foam or other material. 
         [0017]    As used herein, the term “bottom” or “bottom surface” means the underside of a cooling apparatus. 
         [0018]    As used herein, the term “top” or “top surface” means the uppermost side of a cooling apparatus. 
       BACKGROUND 
       [0019]    There are many types of portable coolers known in the art, and in particular many coolers which collapse to facilitate storage. Most coolers have some sort of insulated sides to prevent rapid temperature change. Others utilize removable ice-pack components stored in and inserted within packets or into compartments of a cooler. 
         [0020]    The average size of the freezer compartment in a top/bottom refrigerator/freezer is 4.1 cubic feet, which is not large enough to accommodate a cooler. These freezer compartments generally have one or more shelves which limit the size of the items which the freezer can accommodate. Side by side refrigerators/freezers generally have a larger size freezer, e.g., 9.9 cubic feet; however, they have multiple shelves which maximize the number of items that can be stored while limiting the size of the items. Commercial coolers are also available; however, they are typically used to store other things. 
         [0021]    Coolers known in the art are not specifically designed to be placed in a freezer without disassembly of components. Coolers with hard shells of molded plastic will accumulate frost if left in a freezer for an extended period and when removed from the freezer moisture will form on the outside of the cooler. Coolers having less-rigid vinyl sides are also susceptible to the formation of moisture when removed from a freezer and also to cracking when frozen. 
         [0022]    Ice packs can also offer the ability to store freezing components in the limited space available in a residential-size freezer; however, they offer limited cooling capacity and must generally be inserted separately into coolers. 
         [0023]    Because of the space constraints in freezers and the material from which coolers are constructed, ice packs are inserted into coolers requiring coolers to have several components which need to be removed when the cooler is not in use and re-inserted when a cooler is in use. Ice packs take up a lot of otherwise usable space within the interior of the cooler if they are not designed to compactly fit within the cooler. 
         [0024]    For example, U.S. Pat. No. 4,311,022 (Hall &#39;022) discloses an example of an ice pack. The ice pack constructed of a plurality of separate compartments which are connected together through a webbing assembly allowing the ice pack to be folded into a variety of different shapes. The ice pack must be stored in the freezer and separately inserted into the cooler and again removed after each use. The ice packs can be stored in the freezer, but the cooler cannot be. 
         [0025]    There have been numerous attempts known in the art to create a cooler structure which can be stored in a freezer. One example is disclosed in U.S. Pat. No. 5,582,028 (Rilling &#39;028). Rilling &#39;028 teaches a cooling that is designed to be flexible and adjustable in a way that allows the user to fit the pack closely around a variety of different containers or objects that he or she is trying to keep cold. This cooling pack is also designed to be foldably compact, allowing it to be laid out flat or folded up to conserve storage space when the pack is not in use or being frozen. Although, the cooling device disclosed by Rilling &#39;028 is foldable into a somewhat collapsible position, this attempt is not satisfactory because the cooling pack still requires the removal of one or more components before it is capable of being efficiently stored within a freezer. 
         [0026]    Another example of a portable cooler with permanent frozen inserts is disclosed in U.S. Pat. No. 5,490,396 (Morris &#39;396). Morris &#39;396 teaches a collapsible cooler bag made of a flexible material. A refrigerant gel is enclosed as a layer in between the inner and outer surfaces of the cooler bag. The gel is flexible and the cooler itself are made of flexible material; therefore, the entire container may be compressed or folded in a relatively flat position in order to be easily placed in a freezer so that the gel can be frozen. This attempt is not satisfactory due to the amount of time required to freeze the refrigerant gel. The refrigerant gel is contained within a single compartment inserted between layers and not divided into smaller compartments, which freeze faster. 
         [0027]    Another example of a portable cooler with permanent frozen inserts is disclosed in U.S. Pat. No. 7,302,810 (McCrory &#39;810). McCrory &#39;810 teaches a soft walled cooler composed of two quilted layers. Between these layers are a plurality of permanently attached gel pockets that can be frozen to aid in insulating and cooling the contents stored within. The cooler is foldable in the areas of the walls that fall in between the gel pockets. This design is not desirable because the insulating layers slow down the freezing of the cubes. In addition, the cooler cannot be neatly folded into a flat configuration. 
         [0028]    It is desirable to have a cooling apparatus which includes freezing components that are not inhibited from rapid freezing and are not inhibited by the use of insulating layers. 
         [0029]    It is further desirable to have an integrally constructed cooling apparatus which can be flattened and stored in a residential-size freezer, and is capable of rapid freezing when in a collapsed position. 
         [0030]    It is further desirable to have an integrally constructed cooling apparatus that is less than two to three inches thick when folded to conserve freezer space. 
         [0031]    It is further desirable to have an integrally constructed cooling apparatus which is specially designed to be inserted directly into a freezer. 
       SUMMARY OF THE INVENTION 
       [0032]    The present invention is a unitary cooling apparatus capable of being stored in a freezer and allows the cooling components to freeze in a normal freezing time despite the integral construction of both freezing and insulating components. Channels create circulation of frozen air and this effect is enhanced by reflective elements. 
         [0033]    One embodiment of the apparatus includes a zipper component which extends along the edges of a top surface and bottom surface allowing the top and bottom to be pivoted outward or inward and the cooling apparatus flattened along the seams which connect the four unitary freezing panels. A plurality of cube structures positioned along a plurality of channels allows rapid cooling using a minimum of frozen fluid. 
         [0034]    The unitary freezing panels are comprised of a plurality of layers. The outermost layer is a fabric layer. Next to the fabric layer is an insulation layer followed by an inner reflective layer. A multi-channeled fluid layer containing spaced apart cubes filled with fluid is sandwiched between the inner reflective layer and a polyethylene layer. The polyethylene layer is sewn to the other layers along channels between sets of the cubes. 
         [0035]    When the cooling apparatus is in a flattened position, i.e., top and bottom pivoted flat against cooling apparatus folded along the seams, multiple flattened coolers can be stored in a small space, such as a standard-size freezer. 
       DETAILED DESCRIPTION OF INVENTION 
       [0036]    For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a single component flat cooling apparatus with a multi-channeled fluid layer, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, structures and materials may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention. 
         [0037]    It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements. 
         [0038]    Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. 
         [0039]      FIG. 1  illustrates an exemplary embodiment of unitary cooling apparatuses  100   a - 100   d  stored in a flattened position in freezer  77 . As shown in  FIG. 1 , unitary cooling apparatuses  100   a - 100   d  are extremely space efficient. 
         [0040]      FIG. 2  illustrates an exemplary embodiment of unitary cooling apparatus  100  with multi-channeled fluid layer  40  in an expanded position. Cooling apparatus  100  is comprised of four unitary freezing panels  10   a - 10   d , top surface  20  and bottom surface  30 . Each unitary freezing panel  10   a - 10   d  has multi-channeled fluid layer  40  fixedly attached. Multi-channeled fluid layer  40  is comprised of a plurality of spaced-apart cubes  45  filled with fluid. In the embodiment shown, cubes  45  are rectangular and are filled with purified water. In other embodiments, cubes  45  are of another shape, such as square, circular, or triangular and are filled with a fluid other than water, such as a gel solution. 
         [0041]    Cooling apparatus  100  further includes zippers  50   a ,  50   b . Zipper  50   a  runs along all four sides of top surface  20  and zipper  50   b  runs along four sides of bottom surface  30 . Top surface  20  and bottom surface  30  are attached to cooling apparatus  100  using fabric piece  18   a ,  18   b  (visible in  FIG. 3 ) sewn over the zipper on one edge (i.e., top edge of unitary freezing panel  10   c  and bottom edge of unitary freezing panel  10   c ). Fabric piece  18   a ,  18   b  prevents top surface  20  and bottom surface  30  from being completely unzipped from cooling apparatus  100  and also allow top surface  20  and bottom surface  30  to be pivoted backward and flat. 
         [0042]    When zippers  50   a ,  50   b  are open, top surface  20  and bottom surface  30  can be pivoted outward or inward and unitary freezing panels  10   a - 10   d  can be folded along seams  15   b ,  15   d  (seams  15   a ,  15   c  will be flat) or along seams  15   a ,  15   c  (seams  15   b ,  15   d  will be flat) into a flat configuration. When cooling apparatus  100  is in the collapsed flat configuration, it will easily fit in a standard freezer for freezing the fluid in cubes  45  or into a small space for storage. 
         [0043]    In the embodiment shown, cooling apparatus  100  further includes strap  60 . Strap  60  may be fixedly attached to cooling apparatus  100  (e.g., sewn) or removably attached to cooling apparatus  100  (e.g., hook and loop fasteners or snaps). Cooling apparatus  100  may further include an optional panel insertion channel. For example, cooling apparatus  100  may include an extra panel of fabric on unitary freezing panel  10   a  which allows for easy embroidering or silk screening (plate slides between extra panel and fabric layer). 
         [0044]      FIG. 3  illustrates an exemplary embodiment of unitary cooling apparatus  100  with multi-channeled fluid layer  40  in a collapsed position with top surface  20  and bottom surface  30  pivoted upward. 
         [0045]      FIG. 4  illustrates an exemplary embodiment of unitary cooling apparatus  100  with multi-channeled fluid layer  40  in a collapsed position with top surface  20  and bottom surface  30  pivoted outward and cooling apparatus  100  folded along seams  15   b ,  15   d  so that seams  15   a ,  15   c  are flat. 
         [0046]      FIG. 5  illustrates a side perspective view of an exemplary embodiment of unitary cooling apparatus  100  with multi-channeled fluid layer  40  in a collapsed position with top surface  20  (not visible) and bottom surface  30  pivoted backward. In the embodiment shown, zippers  50   a ,  50   b  (not visible) are open, top surface  20  and bottom surface  30  are pivoted backward against unitary freezing panel  10   c  and cooling apparatus  100  is folded along seams  15   b ,  15   d  (seams  15   a ,  15   c  are flat) into a collapsed position for placing in a freezer or for economical storage. 
         [0047]    Visible are polyethylene layer  48  and cubes  45  of multi-channeled fluid layer  40 . Also visible are channels  44   a - 44   f  between cubes  45  and seams  58   a - 58   d . When cooling apparatus  100  is in an upright position (as in  FIG. 2 ), channels  44   a - 44   f  run vertically between cubes  45 . There are also channels which run horizontally between cubes  45  (not visible); therefore each cube  45  is spaced apart from the cubes surrounding it. 
         [0048]    Multi-channeled fluid layer  40  manufactured in sheets of evenly spaced apart cubes  45 . The sheets are cut to the desired size/number of cubes by cutting between the cubes in the channels. For example, in an exemplary embodiment of cooling apparatus  100 , unitary freezing panels  10   a ,  10   c  may contain four columns of five cubes for a total of twenty cubes and unitary freezing panels  10   b ,  10   d  may contain two columns of five cubes for a total of ten cubes. Polyethylene layer  48  is placed over multi-channeled fluid layer  40  and sewn to inner reflective layer  40  (not labeled) along lanes  58   a ,  58   b  and at seams  15   a - 15   d.    
         [0049]    Opening zippers  50   a ,  50   b  allows air to go flow through cooling apparatus  100  allowing for standard freezing time of cubes  15 . The channels between cubes  45  also aid in the freezing of cubes  45  by exposing a greater surface area of cubes  45  to the cold air. In addition to being important for standard freezing time, the channels allow for flexibility in unitary freezing panels  10   a - 10   d  even when cubes  45  are frozen. 
         [0050]      FIG. 6  illustrates a cross-sectional view of unitary freezing panel  10   a  of an exemplary embodiment of unitary cooling apparatus  100  with multi-channeled fluid layer  40 . In the embodiment shown, each unitary freezing panel  10  of cooling apparatus  100  is comprised of a fabric layer  56 , insulation layer  54 , inner reflective layer  52 , multi-channeled fluid layer  40  and polyethylene layer  48 . In other embodiments, unitary freezing panels  10   a - 10   d  may be comprised of a larger or smaller number of layers. 
         [0051]    In the embodiment shown, fabric layer  56  is comprised of a nylon blend and is water resistant. Additives (“anti-freeze material”) are added to the fibers of the fabric during the manufacturing process which prevents the fabric from cracking when frozen. In other embodiments, fabric layer  56  may be comprised of another material or combination of materials that does not crack during freezing and remains flexible when frozen. 
         [0052]    In the embodiment shown, insulation layer  54  is comprised of notched foam. In other embodiments, insulation layer  54  is comprised of another type of foam or other insulating material known in the art (e.g., fiberglass, coat). 
         [0053]    In the embodiment shown, inner reflective layer  52  is comprised of PE-LD metalized polyethylene. Inner reflective layer  52  reflects cold air back into the interior of the cooler and slowing the passing of cold air through the side of the cooler. Inner reflective layer  52  reduces conductivity and slows molecules helping maintain a lower temperature inside cooling apparatus  100 . In other embodiments, inner reflective layer is made up of another type of reflective material, such as aluminum foil. 
         [0054]    In addition to inner reflective layer  52 , top surface  20  and bottom surface  30  may also include a reflective layer (not shown). 
         [0055]    Multi-channeled fluid layer  40  is comprised of backing layer  46  and top layer  42  which is formed into cubes  45 . In the embodiment shown, backing layer  46  and top layer  42  are comprised of layers of LDPF polyester/nylon that is flexible and does not crack when frozen, is puncture resistant and reduces air flow (i.e., has limited porosity). In other embodiments, top layer  42  and backing layer  46  are comprised of another material with similar properties. This composition of layers allows for a normal freezing time despite the integral construction of both freezing and insulating components. 
         [0056]    Multi-channeled fluid layer  40  is secured to inner reflective layer  52 , insulation layer  54  and fabric layer  56  by polyethylene layer  48 . Polyethylene layer  48  is comprised of food grade, low density polyethylene which is placed over multi-channeled fluid layer  40  and is sewn to inner reflective layer  52  at lanes  58   a - 58   c.

Technology Classification (CPC): 5