Patent Description:
Coolers, ice chests, ice boxes, or the like are commonly used to store contents (e.g., food, beverages, etc.) and keep said contents cool. While many coolers are constructed using durable materials intended for repeated use, other coolers have been manufactured to be disposable. Coolers of the disposable variety are conventionally made from polystyrene foam (i.e., Styrofoam).

Problematically, polystyrene is a non-biodegradable solid that resists chemicals otherwise causing the material to break down. Disposal of polystyrene coolers, consequently, can cause significant environmental harm as discarded polystyrene will persist in the environment for centuries. Many cities and counties across the United States have passed regulations banning sale of polystyrene products for this reason.

Further prior art is known from the documents <CIT>, <CIT> and <CIT>.

The document <CIT> discloses a tub for a container including an inner tub and an outer tub, each formed of a solid compostable or recyclable sheet formed primarily of plant fiber and/or starch. Both the inner tub and the outer tub include a floor, a plurality of side walls that are coupled to the floor along common edges and each coupled to two adjacent side walls along common edges, and a rim provided at a top of the side walls. The rim of the inner tub rests on and is secured to the rim of the outer tub such that the side walls of the inner tub extend downwardly into the space between the side walls outer tub, with the side walls of the outer tub surrounding and spaced apart from the side walls of the inner tub. A volume between the side walls of the inner and outer tub provides a cavity.

The document <CIT> discloses a thermally insulating packaging to hold an item including a solid compostable or recyclable shell that is formed primarily of a plant fiber, and a bottom cover. The shell includes a floor, a plurality of inner side walls that are coupled to the floor, a rim coupled to the plurality of inner side walls, and a plurality of outer side walls that are couple to the rim. The floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space. The plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap. The gap can be an air-filled cavity, or be filled with a compostable or recyclable core material.

The document <CIT> discloses a portable cooler device comprised of recyclable materials. Some embodiments of the device comprise components constructed entirely of, or substantially of, cellulose. Other embodiments may be comprised of recyclable materials not classified as cellulose such as, but not limited to, cotton, bamboo, hemp, or other natural fibers. The specific percentages of recycled and/or recyclable content are not limiting factors for the invention; however, most embodiments have consistent materials of construction such that the entire device may be recycled in a single recycling process without the need for deconstruction. Further, if not recycled, embodiments may be suited to biodegrade within a reasonable amount of time when exposed to the elements in a landfill. Typical embodiments are comprised of an inner shell, an outer shell and pressed cellulose insulating boards sandwiched between the shells.

The present invention provides a single-walled disposable cooler made of a disposable, biodegradable and/or recyclable material, such as a pulp-based material for example. Because the pulp-based material is compostable, recyclable, and/or biodegradable, the cooler can be disposed in an environmentally friendly manner in which the cooler degrades rapidly relative to conventional polystyrene coolers and without toxic residues.

The present invention relates to a single-walled cooler as defined in claim <NUM> and method for manufacturing a single-walled cooler as defined in claim <NUM>.

According to some embodiments, the plurality of support walls are formed continuously or seamlessly from the edges of the base, whereas in other exemplary embodiments, one or more of the support walls are coupled to the corresponding edges of the base non-continuously or with a seam.

The plurality of support walls can be formed with a ledge disposed beneath the upper ends of the plurality of support walls, the ledge being substantially parallel with the base, and the lid can be formed such that outer edges thereof rest on the ledge when the lid covers or substantially covers the opening of the body.

The single-walled disposable cooler can further include a handle wrap structurally independent of the body and the lid, the handle wrap having a cut-out portion formed therein. When the lid covers or substantially covers the opening of the body, the handle wrap can be configured to surround an entirety of the body and the lid in a longitudinal direction such that the cut-out portion is positioned above the body and the lid. The handle wrap can be made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, or alternatively in other embodiments, the handle wrap may be made of a non-biodegradable and/or non-recyclable material.

The body can be formed with a handle portion disposed at an upper region of the body.

The lid can be made entirely of a disposable, biodegradable and/or recyclable material, such as the pulp-based material, or alternatively made of a non-biodegradable and/or non-recyclable material, such as a plastic or other polymer material that may or may not be a disposable, biodegradable and/or recyclable material.

The disposable, biodegradable and/or recyclable material can be a pulp-based material that can be derived from recycled paper. Also, the disposable, biodegradable and/or recyclable material, e.g. a pulp-based material, can be made with a combination of recycled paper and wax. Further, the disposable, biodegradable and/or recyclable material, e.g. a pulp-based material, can include a wax additive. In other exemplary embodiments, the disposable, biodegradable and/or recyclable material can be paper, sugar cane, hemp, bamboo or other materials that are disposable, biodegradable and/or recyclable materials.

The disposable, biodegradable and/or recyclable material, e.g. a pulp-based material, can be compostable, recyclable, and/or biodegradable.

The embodiments described herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identically or functionally similar elements, of which:.

It should be understood that the above-referenced drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the disclosure. The specific design features of the present invention, including, for example, specific dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and use environment.

As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the scope of the present invention defined by the appended claims. Further, throughout the specification, like reference numerals refer to like elements.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Referring now to embodiments of the present invention, the single-walled disposable cooler discussed herein is made of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, or made from paper, sugar cane, hemp, bamboo, or the like. Because the pulp-based material, or other similar type material, is compostable, recyclable, and/or biodegradable, the cooler can be disposed in an environmentally friendly manner in which the cooler degrades rapidly relative to conventional polystyrene coolers and without toxic residues.

The accompanying figures illustrate various embodiments of the disclosed single- walled disposable cooler. As described in detail hereinbelow, <FIG> include views of a single-walled disposable cooler according to a first embodiment of the present invention; <FIG> include views of exemplary single-walled disposable coolers not forming part of the present invention; and <FIG> include views of a single-walled disposable cooler which is not in accordance with the invention, however, shows a handle wrap which can be used in combination with a cooler according to the invention.

As illustrated in each of the figures, the single-walled disposable cooler (hereinafter "cooler") <NUM> can include a single-walled disposable shell, made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, paper, sugar cane, hemp, bamboo, or similar type material, defining a body <NUM>. The body <NUM> includes a base <NUM> and a plurality of support walls <NUM> coupled to the base <NUM>. One or more of the plurality of support walls <NUM> may be attached to an edge of the base <NUM>, such as by an adhesive or some other similar attachment mechanism, or alternatively, one or more of the plurality of support walls <NUM> extend continuously or seamlessly from the edges of the base <NUM>. At least one of the support walls <NUM> includes an entirely planar surface.

That is, the support walls <NUM> can be formed such that the surface of at least one support wall <NUM> is disposed entirely in a single plane. In one example, two support walls <NUM> disposed on opposite sides of the base <NUM> can include entirely planar surfaces, respectively, while two other support walls <NUM> disposed on opposite sides of the base <NUM>, each of which is substantially perpendicular to the two entirely planar support walls <NUM>, can include non- entirely planar surfaces, respectively.

The support walls <NUM> and the base <NUM> define an interior cavity <NUM> of the body <NUM>. The support walls <NUM> extend upwardly from the base <NUM> to form an opening <NUM> at an upper terminus of the body <NUM>. The opening <NUM> is in fluid communication with the interior cavity <NUM> of the body <NUM>.

Notably, forming at least one of the support walls <NUM> with an entirely planar surface can maximize the volume of the interior cavity <NUM>, allowing for greater storage capacity in the cooler <NUM>.

The body <NUM> can be formed to include various features. For instance, the body <NUM> can be formed with one or more handle portions disposed at an upper region of the body <NUM>. In one example, the support walls <NUM> can be formed with a ledge <NUM> disposed beneath the upper ends of the support walls <NUM>. The ledge <NUM> can be substantially parallel with the base <NUM>. The ledge <NUM> can therefore function as a handle portion where a user grips an exterior portion of the ledge <NUM> for transport of the cooler <NUM>.

Specifically, the user can wrap his or her fingers under the inwardly extending portion of the ledge <NUM>. Moreover, central portions of the support walls <NUM> can be formed with indentations so as to produce additional room under the ledge <NUM> for an improved grip.

The cooler <NUM> futher includes a lid <NUM> capable of covering or substantially covering the opening <NUM> of the body <NUM>. In this regard, the lid <NUM> is configured to reversibly couple with the body <NUM> of the cooler <NUM> in any of a variety of ways, some of which are described herein across the various embodiments. The lid <NUM> can be shaped in conformity with the opening <NUM> of the body <NUM>. The lid <NUM> can be formed to include various features. For instance, the lid <NUM> can be formed with one or more cup holders <NUM> disposed on a top portion thereof. The one or more cup holders <NUM> can be formed into the top portion of the lid <NUM> in any suitable configuration. Characteristics such as the dimensions, positioning, and number of the one or more cup holders <NUM> can vary. One or more handle portions <NUM> are formed into the lid <NUM>, as discussed in greater detail below.

Notably, the body <NUM> and the lid <NUM> of the cooler <NUM> can be made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material.

Alternatively, the body <NUM> is made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, and the lid <NUM> can be made of a non- biodegradable and/or non-recyclable material, such as a plastic, other polymer material, or other known material type that can be used for coolers.

Pulp, as is generally known in the art, is a fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, recycled paper, straw, grass, or other raw fibrous materials.

Pulp is understood to be more eco-friendly than polystyrene, as pulp can be biodegradable (i.e., capable of disintegrating into an innocuous material), recyclable (i.e., capable of being reused or treated for reuse), and/or compostable (i.e., capable of decomposing within <NUM>-<NUM> days), without release of toxic residues upon decomposition.

In some cases, the pulp-based material from which the cooler <NUM> is made can derive entirely from pre-consumer recycled paper. In other cases, the pulp-based material from which the cooler <NUM> is made can derive from a combination of the recycled paper and a wax additive (e.g., paraffin wax) added to enhance the water resistance of the cooler <NUM>. In yet other cases, a small amount of rosin (a solid form of resin) can be added to the pulp-based material to enhance the cooler's durability. It is understood, however, that the pulp-based material can be derived from any suitable pulp-producing materials generally known in the art. Additionally, the body <NUM> can be formed from other disposable, biodegradable and/or recyclable material such as paper, sugar cane, hemp, bamboo, and other similar type materials. The lid <NUM> also may optionally be formed from pulp-based materials or other disposable, biodegradable and/or recyclable material such as paper, sugar cane, hemp, bamboo, and other similar type materials. Alternatively, the lid <NUM> is formed from non- biodegradable and/or non-recyclable materials.

Referring now to <FIG>, the lid <NUM> is formed so as to fit inside of the upper ends of the plurality of support walls <NUM> according to a first embodiment of the present invention. <FIG> illustrates a perspective view of the cooler <NUM> according to the first embodiment of the present invention; <FIG> illustrates a front view of the cooler <NUM> according to the first embodiment of the present invention; <FIG> illustrates a side view of the cooler <NUM> according to the first embodiment of the present invention; <FIG> illustrates a top view of the cooler <NUM> according to the first embodiment of the present invention; <FIG> illustrates a bottom view of the cooler <NUM> according to the first embodiment of the present invention; and <FIG> illustrates a cross-sectional front view of the cooler <NUM> according to the first embodiment of the present invention.

As shown in <FIG>, the support walls <NUM> can be formed with a ledge <NUM> disposed beneath the upper ends of the support walls <NUM>. The ledge <NUM> can be formed so as to be substantially parallel with the base <NUM>, as described above. The lid <NUM> can be formed such that outer edges thereof rest on an interior surface of the ledge <NUM> when the lid <NUM> covers or substantially covers the opening <NUM> of the body <NUM>.

The lid <NUM> is formed with a handle portion <NUM> disposed at a central region thereof.

The handle portion <NUM> can enable a user to grip a top surface of the lid <NUM> in order to remove the lid <NUM> from the opening <NUM> of the body <NUM>. The handle portion <NUM> can be formed in any manner suitable for a user's grip. In one example, the handle portion <NUM> can include a portion of the lid <NUM> which protrudes outwardly from an indentation region <NUM>, as shown in <FIG>. In another example, the handle portion <NUM> can include an elongated aperture (not shown) formed into a portion of the lid <NUM> protruding outwardly from a top surface of the lid <NUM>. The elongated aperture can be formed to enable a user to insert his or her fingers therethrough.

Referring now to <FIG>, the lid <NUM> can be formed such that outer edges thereof are positioned outside of the plurality of support walls <NUM> in a lateral direction when the lid <NUM> covers the opening <NUM> of the body <NUM> according to a first illustrative example of the present disclosure. <FIG> illustrates a perspective view of the cooler <NUM> according to the first illustrative example of the present disclosure; <FIG> illustrates a front view of the cooler <NUM> according to the first illustrative example of the present disclosure; <FIG> illustrates a side view of the cooler <NUM> according to the first illustrative example of the present disclosure; <FIG> illustrates a top view of the cooler <NUM> according to the first illustrative example of the present disclosure; and <FIG> illustrates a cross-sectional front view of the cooler <NUM> according to the first illustrative example of the present disclosure.

As shown in <FIG>, the outer edges of the lid <NUM> can extend downwardly below upper ends of the support walls <NUM>. In this configuration, the lid <NUM> can fully cover the upper ends of the support walls <NUM>, i.e., the rim of the body <NUM>, as well as the opening <NUM> of the body <NUM>. A user may be capable of the lifting the lid <NUM> from the opening <NUM> of the body <NUM> by gripping the outer edges of the lid <NUM> and pulling upwards.

Referring now to <FIG>, the lid <NUM> can be formed such that outer edges thereof are substantially flush with upper ends of the plurality of support walls <NUM> when the lid <NUM> covers the opening <NUM> of the body <NUM> according to a second illustrative example of the present disclosure. <FIG> illustrates a perspective view of the cooler <NUM> according to the second illustrative example of the present disclosure; <FIG> illustrates a front view of the cooler <NUM> according to the second illustrative example of the present disclosure; <FIG> illustrates a side view of the cooler <NUM> according to the second illustrative example of the present disclosure; and <FIG> illustrates a cross-sectional side view of the cooler <NUM> according to the second illustrative example of the present disclosure.

As shown in <FIG>, the body <NUM> can be formed with a handle portion <NUM> disposed at an upper region thereof. In this configuration, the handle portion <NUM> can include an indentation region formed into a portion of the upper ends of the support walls <NUM>, enabling a user to grip a bottom surface of the lid <NUM>. The user, gripping the bottom of the lid <NUM> within the aforementioned indentation region of the body <NUM>, can pull the lid <NUM> upwards to remove the lid <NUM> from the opening <NUM> of the body <NUM>.

Referring now to <FIG>, the cooler <NUM> can further include a handle wrap <NUM> structurally independent of the body <NUM> and the lid <NUM> according to a second embodiment of the present invention. <FIG> illustrates a perspective view of the cooler <NUM> according to the third illustrative example of the present disclosure. <FIG> illustrates a front view of the cooler <NUM> and <FIG> illustrates a side view of the cooler <NUM>.

As shown in <FIG>, the handle wrap <NUM> can be formed with a cut-out portion <NUM> shaped in a manner allowing a user to insert his or her fingers therethrough. When the lid <NUM> covers the opening of the body <NUM>, the handle wrap <NUM> can be configured to surround an entirety of the body <NUM> and the lid <NUM> in a longitudinal direction such that the cut-out portion <NUM> is positioned above the body <NUM> and the lid <NUM>. The handle wrap <NUM> can provide for transport of the cooler <NUM> without the need to form a physical handle portion into either of the body <NUM> or lid <NUM>.

In this configuration, the lid <NUM> can be formed such that outer edges thereof are substantially flush with upper ends of the plurality of support walls <NUM> when the lid <NUM> covers or substantially covers the opening <NUM> of the body <NUM>, as shown in <FIG>. However, the cooler <NUM> is not limited as such.

Like the body <NUM>, the handle wrap <NUM> can be made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material. Thus, when the cooler <NUM> includes the handle wrap <NUM>, all components of the cooler <NUM> (i.e., body <NUM>, lid <NUM>, and handle wrap <NUM>) can be compostable, recyclable, and/or biodegradable.

Alternatively, the handle wrap <NUM> can be made of a non-biodegradable and/or non- recyclable material, such as a plastic, rubber or rubber-like material, or other suitable material that is not biodegradable or recyclable.

Pursuant to any of the embodiments described above and referring to <FIG>, the body <NUM> of a second cooler <NUM> can be stackable with the body <NUM> of a first cooler <NUM> according to some embodiments. In those embodiments, each of the plurality of support walls <NUM> of each cooler <NUM> is oriented outwardly (not perpendicular) from the base <NUM> so that the opening <NUM> that is formed at the distal ends of the support walls <NUM> is larger than the base <NUM>. The base <NUM> of the second cooler <NUM> is insertable into the opening <NUM> of the first cooler <NUM>, such that the second cooler <NUM> slides downwardly into the interior cavity <NUM> of the first cooler <NUM>. Similarly, the body <NUM> of a third cooler <NUM> can slide into the interior cavity <NUM> of the second cooler <NUM>. This can be repeated as the bodies <NUM> of the coolers <NUM> is stackable with one another.

Accordingly, the single-walled disposable cooler described herein is made of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, that is compostable, recyclable, and/or biodegradable. As a result, the cooler can be disposed in an eco-friendly manner in which the cooler disintegrates in a compost environment rapidly relative to conventional polystyrene coolers and without leaving toxicity into the soil. The disposable, biodegradable and/or recyclable material, such as a pulp-based material, used for fabricating the single-walled cooler described herein can comply with modern regulations prohibiting sale of polyethylene products, while providing consumers with a storage solution that is disposable. Moreover, the single-walled disposable cooler described herein can include convenient features such as cup holders, handles, and the like, and reliably retain water for several days upon adding a wax additive to the pulp-based material used to construct the cooler.

The foregoing description has been directed to certain embodiments of the present disclosure. It will be apparent, however, that other variations and modifications may be made to the described embodiments, with the attainment of some or all of their advantages.

Claim 1:
A single-walled cooler (<NUM>) comprising:
a body (<NUM>) including a base (<NUM>) and a plurality of support walls (<NUM>) coupled to the base (<NUM>), at least one of the plurality of support walls (<NUM>) including an entirely planar surface, the plurality of support walls (<NUM>) and the base (<NUM>) defining an interior cavity (<NUM>) of the body (<NUM>), and the plurality of support walls (<NUM>) extending upwardly from the base (<NUM>) to form an opening (<NUM>) at an upper terminus of the body (<NUM>) in fluid communication with the interior cavity (<NUM>); and
a lid (<NUM>) configured to reversibly couple with the body (<NUM>), the lid (<NUM>) shaped to at least substantially cover the opening (<NUM>) of the body (<NUM>),
wherein the body (<NUM>) is made entirely of a disposable, biodegradable and/or recyclable material, the disposable, biodegradable and/or recyclable material being a pulp-based material;
characterized in that
the lid (<NUM>) is formed so as to fit inside of upper ends of the plurality of support walls (<NUM>) and the lid (<NUM>) is formed with a handle portion (<NUM>) disposed at a central region thereof.