Abstract:
The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing mobile cooler assembly. The integrated connection of the side walls, front, back, cover and bottom panel components simplifies cooler assembly construction. The panels are formed of injection molded plastic to interlock with one another without the need for fasteners or connectors. The system incorporates a minimum number of components by integrally forming the connectors into the panels which are snapped together to complete the assembly.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to a mobile cooler station. More specifically, the present invention relates to a cooler station assembly utilizing injection molded plastic structural panels having integrally formed connectors. The cooler station is capable of being packaged and shipped in a knock-down state and assembled into a secure and decorative cooler without additional fasteners.  
       BACKGROUND OF THE INVENTION  
       [0002]     Portable or mobile coolers are very convenient for outdoor picnics and cook outs. A common form of a portable cooler is the well known ice chest which comprises a molded, insulated container with a top hingedly connected thereto. These containers are available in various sizes and forms. However, they do not include a provision for the storage of glasses or other containers prior to their use in the service of cold beverages. Furthermore, certain foods require refrigeration or being kept at a cooler temperature prior to their preparation. Normally these foods are kept in separate, non-disposable, containers from which they are removed just prior to their preparation. The necessity of storing these containers after the foods are removed therefrom and prior to their being returned inside the house becomes problematic. This invention solves these problems by providing storage areas for these containers.  
       DESCRIPTION OF THE PRIOR ART  
       [0003]     An example of the well known portable ice chest is U.S. Pat. No. 4,976,448 which discloses a portable cooler onto which wheels are mounted for ease of mobility. This cooled has no provisions for the storage of glasses or other items.  
         [0004]     U.S. Pat. No. 5,480,170 discloses a portable cooler which is provided with wheels for mobility and telescoping legs for stability once the cooler has been moved to the desired location. Hinged trays are mounted on the sides of the cooler to provide support for foods, beverages and food containers. However, there are no provisions for storage of the food containers after their use.  
         [0005]     U.S. Pat. No. 5,876,047discloses another portable including wheels for mobility. The cooler top is hinged to provide a support for food and beverages. Hinged trays are attached to the sides of the cooler for support of food and beverages. A storage compartment is provided adjacent the cooler. While this cooler provides a storage compartment it is inconvenient to use. As a result of its relative low height the user must constantly bend over to use it.  
         [0006]     Such prior art coolers, while working well, have not met all of the needs of the manufacturers, retailers or end users by providing a cooler station that can be easily manufactured, packaged and shipped to the consumer in a knock-down state. Nor have they met the needs of the end users who require structural integrity combined with a pleasing aesthetic appearance and ease of assembly without the need for tools and small fasteners for assembly.  
         [0007]     High among these needs is a mobile cooler station having walls which resist panel separation, buckling, racking and weather infiltration. Structural integrity is a further consideration. The cooler station formed by the panels must tie into the cover and bottom in such a way as to unify the entire enclosure. Also, from a safety standpoint, a cover should be present which can be easily opened and retained in the open position while the cooler is being accessed.  
         [0008]     Finally, there are ergonomic needs that a mobile cooler station must satisfy in order to achieve acceptance by the end user. The cooler station assembly must be easily and quickly assembled using minimal or no hardware and requiring a minimal number of tools. Further, the cooler station assembly must not require excessive strength to assemble or include heavy component parts. The cooler station assembly must assemble together in a manner which will not detract from the internal storage volume.  
       SUMMARY OF THE INVENTION  
       [0009]     The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing mobile cooler station. The integrated connection of the side walls, cover and bottom panel components simplifies the cooler construction. The panels are formed from injection molded plastic to interlock with one another without the need for separate metal fasteners or connectors. The system incorporates a minimum number of components by integrally forming the connectors into the injection molded panels which are snapped together to complete the assembly. This construction eliminates the need for separate connectors or fasteners to assemble the cooler station assembly. Injection molding allows the panels to be formed with a single wall having integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or rotationally molded assemblies. The same side wall and bottom panels components can be used to create a variety of different assemblies useful for cookouts or outdoor entertaining and the assembly of these requires minimal hardware and a minimum number of hand tools.  
         [0010]     The base, support, front and back wall panels have integrally formed outwardly projecting bosses for interlocking engagement with the left and right side wall panels. The left and right side wall panels are constructed with integrally formed inwardly contoured sockets for interlocking cooperative engagement with the bosses on the edges of the base, support, front and back wall panels. The engagement between the bosses and the sockets serve to rigidly connect the components together into a weather resistant assembly. The system further includes a one-piece latching cover which is hingedly connected and latched in place after the front, back, support, side and bottom panels have been fully assembled.  
         [0011]     The cover panel is hingedly connected to removable and replaceable hinge inserts thereby providing an opening for access to the interior of the cooler. The cover is provided with flexible supports on either or both sides thereof to maintain the cover in its open position.  
         [0012]     The lower surface of the base panel includes integrally formed bosses constructed and arranged to cooperate with casters to allow for easy movement of a full or empty cooler. The lower portion of the back wall panel is provided with an opening through which a drain hose can pass for the removal of water from the cooler.  
         [0013]     Accordingly, it is an objective of the instant invention to provide a mobile cooler station composed of panels with integral connectors.  
         [0014]     It is a further objective of the instant invention to provide a mobile cooler assembly with panels formed by injection molding for increased structural integrity.  
         [0015]     It is another objective of the instant invention to provide a mobile cooler assembly wherein the side walls, cover, support and bottom panels are integrally interlocked without the use of separate fasteners or connectors.  
         [0016]     It is still another objective of the invention to provide a mobile cooler assembly constructed of modular panels having an aesthetically pleasing appearance.  
         [0017]     It is still a further objective of the invention to provide a mobile cooler assembly that is capable of being packaged and shipped in a knock-down state and constructed into a secure assembly at a desired site.  
         [0018]     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0019]      FIG. 1  is a perspective view of the mobile cooler assembly of the instant invention.  
         [0020]      FIG. 2  is an exploded view of the mobile cooler assembly shown in  FIG. 1 .  
         [0021]      FIG. 3  is a partially exploded view of a side panel and the lower portion of the mobile cooler assembly.  
         [0022]      FIG. 4  is a perspective of the outer portion of the cooler assembly in a partially state.  
         [0023]      FIG. 5  is a perspective view of the rear portion of the mobile cooler assembly with the cover removed.  
         [0024]      FIG. 6A  is a perspective view of the mobile cooler assembly with cover in its raised position.  
         [0025]      FIG. 6B  is a partial view of the cover showing the latch.  
         [0026]      FIG. 7  is a perspective view of the bottom of the mobile cooler assembly.  
         [0027]      FIG. 8  is a perspective view of the mobile cooler assembly and the tub.  
         [0028]      FIG. 9  is a top perspective view of the mobile cooler assembly.  
         [0029]      FIG. 10  is a top perspective view of the mobile cooler assembly and a cover support.  
         [0030]      FIG. 11A  is a top perspective view of the mobile cooler assembly and the cover support including the cover.  
         [0031]      FIG. 11B  is a partial view of the cover illustrating the attachment of the support to the cover. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.  
         [0033]      FIGS. 1 and 2  now referenced illustrate perspective and exploded views of the mobile cooler station, generally referenced as  10 , according to a preferred albeit non-limiting embodiment of the invention. The mobile cooler station assembly comprises a base panel  100 , a right side panel  200 , a left side panel  300 , a back panel  400 , a front panel  500 , a cover panel  600  and a support panel  700 . In the preferred embodiment the panels are formed of, but not limited to, a suitable plastic such as polystyrene, polypropylene, or polyethylene, through the process of injection molding. The result is that the panels forming the cooler station assembly  10  are formed as unitary single wall panels with integral connectors and cross bracing. Strengthening ribs  102  are formed within the inner surfaces of the side panels, front panel, and back panel to enhance rigidity of the panels as shown in  FIGS. 1 and 2 . The base panel has a top surface  104 , bottom surface  106 , front edge  108 , back edge  110 , left edge  112 , and right edge  114  ( FIG. 3 ). Integrally formed along the left and right base panel edges are a plurality of bosses  116  for attaching the base panel to the left and right panels. The bosses  116  extend outwardly from each edge to cooperate with sockets  210  extending inwardly along the bottom portions  206 ,  306  of the right and left side panels respectively. The bosses and sockets are constructed and arranged so that the bosses  116  mateably engage the sockets  210 , securing the panels together in a perpendicular and inter-fitting engagement. Detent or spring lock fasteners  118  cooperate with apertures  208  to secure the bosses  116  to the sockets  210 . Those skilled in the art can appreciate that the spring lock fasteners  118  can be used throughout the cooler station  10  to mount or secure components to one another thereby facilitating assembly of the cooler station from an unassembled condition. The overlapping boss  116  and socket  210  arrangement increases the structural integrity of the cooler station  10  by preventing the panels  200 ,  300 ,  400 , and  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the cooler station. Also integrally formed on the bottom of the base panel are gussets  106  which add structural rigidity and strength to the base ( FIGS. 6A and 7 ).  
         [0034]     The right panel  200  is configured with a first edge  212  and a second edge  214 . Both edges  212  and  214  include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with the bosses  116  provided along either edge of the back panel  400  and the front panel  500 .  
         [0035]     The left panel  300  is configured having a first edge  312  and a second edge  314 . Both edges  312  and  314  include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with bosses  116  provided along either edge of the back panel  400  and the front panel  500 .  
         [0036]     The outer surface of the panels  200 ,  300 ,  400 , and  500  are constructed generally smooth having a plurality of inwardly curved grooves  230  for added strength and aesthetic appearance. The inside of the panels  200 ,  300 ,  400 ,  500  are constructed with a plurality of strengthening ribs  202  extending along and across the panels. The ribs  202  and inwardly curved grooves  230  increase the structural integrity of the cooler station  10  by preventing the panels  200 ,  300 ,  400 , and  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the cooler station  10 . The integrally formed ribs  202  and inwardly curved grooves  230  are facilitated by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or rotational molding as utilized in the prior art. In this manner the cooler station of the instant invention is capable of handling a significant amount of weight as compared to prior art cooler stations.  
         [0037]     The right and left side panels  200  and  300  are attached to the base panel  100  by inserting the bosses  116  into the sockets  210  until the spring lock fasteners  118  engage the apertures  208  in the sockets  210  of the right  200  and left  300  panels ( FIG. 3 ). The front and back panels  400  and  500  are attached to the right  200  and left  300  panels by inserting the elongated bosses  116  into sockets  210  until the spring lock fasteners  118 , integrally formed into the bosses  116 , engage the apertures  208  in the sockets of the right and left panels  200  and  300 . It will be appreciated that the purposes of the elongated bosses  116  are to align the two panels in a perpendicular relationship and to facilitate their mechanical connection. The resulting mobile cooler station benefits from high structural integrity and reliable operation.  
         [0038]     Referring to  FIGS. 5, 6A  and  6 B, perspective views of the cooler station are shown illustrating the pivotal operation of the cover panel  600  and latch assembly. Also illustrated is the construction and arrangement of the separable and replaceable hinge assemblies. The hinge assemblies generally include a pair of hinge inserts  650  ( FIG. 5 ), each having a hinge  652 . The hinges are constructed and arranged to cooperate with a plurality of hinge receivers  602  located on the back edge  610  of the cover  600  to allow pivotal movement of the cover panel  600  between and open position illustrated in  FIG. 2  and a closed position illustrated in  FIG. 1 . The hinges are integrally formed onto the upper portion of the hinge inserts  650 . The hinge receivers  602  are sized to fit over and encompass their respective hinges  652 . A pin  654  passes through the hinge and hinge receiver to couple them together in a pivotal assembly.  
         [0039]     The cover panel  600  is releasably secured in the closed position by pivoting the cover panel downward until the cover latch  622 , mounted on the cover panel, engages at least one indentation  620  formed in the front top portion of the front panel  500 . This results in a positive mechanical connection. To open the cover panel the latch  622  is pulled outwardly until it releases from indentation  620  and then the cover is pivoted upwardly.  
         [0040]     Referring now to  FIG. 3  the support panel  700  is attached to the right and left side panels  200  and  300  by inserting bosses  116 , integrally formed on the support panel, into the sockets  210 , integrally formed in the side panels, until the spring lock fasteners  118 , located on the bottom portion of the boss  116 , engage the apertures  208  in the sockets  210  of the side panels.  
         [0041]     Referring now to  FIG. 2  the front panel  500  is attached to the right and left side panels  200  and  300  by inserting bosses  116 , integrally formed on the front panel, into sockets  210 , integrally formed in the side panels, until the spring lock fasteners  118  engage the apertures  208  in the sockets  210  of the side panels. The back panel  400  is attached to the right and left side panels in a very similar manner. Bosses  116 , integrally formed on the back panel  400 , are inserted into sockets  210 , integrally formed in the side panels, until the spring tabs  118  engage apertures  208  in the sockets  210  of the side panels. At the top of the edge  212  of the right side panel and top of the edge  312  of the left side panel are inserts  220  which close off the channels formed in the edge portions of the side panels by the injection molding of the sockets  210 .  
         [0042]     The perpendicular panels are brought into an overlapping relationship wherein the bosses  116  enter the corresponding sockets  210  in the right and left panels  200  and  300  respectively. The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection therebetween and provides several advantages. Among these advantages are first, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock which prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another.  
         [0043]     Referring now to  FIGS. 2 and 7 , the casters  120  and caster bosses  122  are illustrated. The casters include a stem  124  which is constructed and arranged to cooperate with an aperture  126  integrally formed into the lower surface of the base panel  100 . To assemble the caster, the stem  124  is inserted into the aperture  126  of the boss  122  until a retainer ring snaps into a corresponding groove formed in the aperture resulting in a mechanically secure connection. A releasable lock  130  for the casters is also provided to prevent the mobile cooler station from unwanted moves on sloped and uneven surfaces.  
         [0044]     Located below the front panel  500  is a door  502  providing assess to a storage area. The storage area is located below the support panel  700 , above the base panel  100 , and between the right and left side panels  200  and  300 . The area may be used for the storage of items associated with the serving of cold beverages or other chilled items. The door  502  is hingedly mounted to the base panel and support panel by hinge pins  504  integrally formed in the door. The hinge pins fit into and cooperate with apertures  506  integrally formed in the support panel and the base panel to allow pivotal opening and closing of the door. A handle  508  may also be provided on the door to assist the opening and closing thereof.  
         [0045]     Referring now to  FIGS. 2, 8  and  9 , a tub  800  is illustrated. The tub serves as a container to hold the chilled beverages and other items in addition to the ice or other cooling means. The tub is surrounded by insulation panels  810  mounted to the side panels, the back panel, the front panel, the support panel and the cover. A preferred method of mounting the panels utilizes pins  812 , integrally formed in the side, back, front, and support panels and cover. The insulation, which may be in the form of sheets, is pressed onto the pins  812  and held thereon by friction. A rim  802  ( FIG. 2 ) completely surrounds the top perimeter of the tub and spans the space between the tub and the adjacent panels. The rim is installed after the tub is inserted into the cooler station. This rim permits easy installation of the tub into the assembled cooler station while preventing any objects from entering the space between the tub and the adjacent panels. The tub is also provided with a drain  804  ( FIG. 9 ) located in the bottom thereof. The drain is provided with a valve  806  to allow fluid which has accumulated in the tub to be drained away when it is convenient. A drain hose  808  is connected to the drain at one end thereof and the opposite end passes to the exterior of the cooler station through an opening  402  located in the lower portion of the back panel  400  ( FIG. 5 ).  
         [0046]     Referring now to  FIGS. 10 and 11 A, a support  602  extends between the cover and one or both side panels. In the case where the support extends between both side panels and the cover, two separate supports are employed. The support is mounted at one end thereof to a side panel utilizing an integrally formed mount  604 . The other end of the support is mounted to the cover utilizing an integrally formed mount  606  ( FIG. 11B ). This end of the support is formed with a connector  608  which allows the support to be easily connect to or removed from mount  606 . When the cover is open the support is fully extended and rigid thereby supporting the cover in its open position. When the cover is closed, the support folds over on itself to allow it to fit into a groove and not interfere with the closing of the cover.  
         [0047]     Referring to  FIGS. 1 and 2  a shelf  205  is hingedly mounted to the right side panel  200  by a plurality of hinges  207 . The hinges are removably mounted to apertures formed in the side panel so as to be attachable and removable without the use of tools. The shelf is constructed and arranged to be in either a downwardly folded position adjacent the side panel or an upwardly extended position (not shown). In the downward position the shelf is not in use and folded out of the way. In the upward position the shelf is horizontally extended away from the side panel and capable of supporting objects placed thereon. One of the hinges  207  is preferable spring loaded so as to enable the shelf to be inserted onto and removed from the side panel.  
         [0048]     A rack  206  is mounted on the opposite side panel from the shelf. The rack has two extensions  208  which engage apertures in the side panel to mount the rack thereto. These are the same apertures to which the hinges  207  are mounted. The rack may be attached and removed without the use of tools. The rack may be employed to hang things on such as towels or food service implements.  
         [0049]     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.  
         [0050]     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.  
         [0051]     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.