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. Documents <CIT>, <CIT> and <CIT> disclose disposable coolers.

It is provided a double-walled, slip fit disposable cooler according to claim <NUM>. The examples 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:.

The accompanying figures illustrate various embodiments of the disclosed double-walled, slip fit cooler. As described in detail hereinbelow <FIG> shows a perspective view of a double-wall, slip fit cooler in accordance with a first embodiment of the present invention. <FIG> shows a perspective view of the double-wall, slip fit cooler of <FIG> having a lid removed and an inner liner raised in accordance with the first embodiment of the present invention. <FIG> shows a cross-sectional view of the double-wall, slip fit cooler of <FIG> in accordance with the first embodiment of the present invention. <FIG> shows a cross-sectional view of the double-wall, slip fit cooler of <FIG> without the lid in accordance with the first embodiment of the present invention. <FIG> shows a cross-sectional view of the double-wall, slip fit cooler without the lid in accordance with a second embodiment of the present invention.

<FIG> shows a perspective view of a double-wall, slip fit cooler <NUM> in accordance with a first embodiment of the present invention. <FIG> shows a perspective view of the double-wall, slip fit cooler <NUM> of <FIG> having a lid <NUM> removed and an inner liner <NUM> raised in accordance with the first embodiment of the present invention. <FIG> shows a cross-sectional view of the double-wall, slip fit cooler <NUM> of <FIG> in accordance with the first embodiment of the present invention. <FIG> shows a cross-sectional view of the double-wall, slip fit cooler <NUM> of <FIG> without the lid <NUM> in accordance with the first embodiment of the present invention. Referring to <FIG>, the double-walled, slip fit disposable cooler <NUM> will be described in accordance with the first embodiment of the present invention.

The double-walled, slip fit cooler <NUM> includes a body <NUM> and a lid <NUM> according to some exemplary embodiments. However, the doubled-walled, slip fit cooler <NUM> may include additional features, such as a strap to be used as a handle, without departing from the scope and spirit of the exemplary embodiment. The body <NUM> includes an outer shell <NUM> and an inner liner <NUM> disposed substantially within the outer shell <NUM>. Each of the outer shell <NUM> and the inner liner <NUM> are 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 according to some exemplary embodiments, but one or more of the outer shell <NUM> and the inner liner <NUM> can be made of a different material.

The outer shell <NUM> includes a base <NUM>, a plurality of support walls <NUM> coupled to the base <NUM>, and a lip <NUM> extending substantially horizontally and then upwardly from the distal ends of the support walls <NUM> away from the base <NUM>. According to the exemplary embodiment, the outer shell <NUM> is fabricated as a single component that is continuous and seamless. However, in other exemplary embodiments, at least one of the plurality of support walls <NUM> may be attached to an edge of the base <NUM> or to another support wall <NUM>, such as by an adhesive or some other similar attachment mechanism. At least one of the support walls <NUM> can include 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. For example, the two oppositely disposed, non-planar surface support walls <NUM> includes a channel <NUM> extending centrally from the lower end of the support wall <NUM> to the upper end of the support wall <NUM> where the lip <NUM> is formed. This channel <NUM>, in combination with the lip <NUM>, facilitates a user in lifting and transporting the cooler <NUM> from one location to another. The support walls <NUM> and the base <NUM> can define an interior cavity <NUM> of the outer shell <NUM>. The support walls <NUM> can extend upwardly from the base <NUM> to form an opening <NUM> at an upper terminus of the outer shell <NUM>. The opening <NUM> can be in fluid communication with the interior cavity <NUM> of the outer shell <NUM>. In some embodiments, the lip <NUM> includes a horizontal lip wall <NUM> and a vertical lip wall <NUM>. The horizontal lip wall <NUM> extends outwardly away from the opening <NUM> at the distal end of each support wall <NUM>; however, in other embodiments, the horizontal lip wall <NUM> may extend inwardly into the opening <NUM> at the distal end of each support wall <NUM>. The vertical lip wall <NUM> extends substantially upward away from the base <NUM> at the end of the horizontal lip wall <NUM> when the horizontal lip wall <NUM> extends outwardly away from the opening <NUM> at the distal end of each support wall <NUM>. However, in embodiments where the horizontal lip wall <NUM> extends inwardly into the opening <NUM> at the distal end of each support wall <NUM>, the vertical lip wall <NUM> continues to extend upwardly along each of the support walls <NUM> away from the base <NUM> at the location where the distal end of each of the support walls <NUM> meet with the horizontal lip wall <NUM>.

Similarly, the inner liner <NUM> includes a base <NUM>, a plurality of support walls <NUM> coupled to the base <NUM>, and a lip <NUM> extending substantially horizontally from the support walls <NUM> at a distal end from the base <NUM>. According to the exemplary embodiment, the inner liner <NUM> is fabricated as a single component that is continuous and seamless. However, in other exemplary embodiments, at least one of the plurality of support walls <NUM> may be attached to an edge of the base <NUM> or to another support wall <NUM>, such as by an adhesive or some other similar attachment mechanism. At least one of the support walls <NUM> can include 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> can define an interior cavity <NUM> of the inner liner <NUM>. The support walls <NUM> can extend upwardly from the base <NUM> to form an opening <NUM> at an upper terminus of the inner liner <NUM>. The opening <NUM> can be in fluid communication with the interior cavity <NUM> of the inner liner <NUM>. In some embodiments, the lip <NUM> extends outwardly away from the opening <NUM> at the distal end of each support wall <NUM>.

Once the inner liner <NUM> is disposed into the interior cavity <NUM> of the outer shell <NUM>, such that the inner liner's base <NUM> is positioned adjacent the outer shell's base <NUM>, the inner liner's lip <NUM> is aligned with, sitting atop of, and is supported by the outer shell's lip <NUM>, and in particular, the horizontal lip wall <NUM> according to some exemplary embodiments. The inner liner's lip <NUM> is not coupled to the outer shell's lip <NUM>, i.e. the outer shell's horizontal lip wall <NUM>; and therefore, the inner liner <NUM> is removable from the outer shell <NUM>. This feature of having the inner liner <NUM> removable from the outer shell <NUM> allows an end-user to easily clean those components and also replace either of the components that may require replacing in the future without the need to purchase an entire cooler <NUM>. Also, once the inner liner <NUM> is disposed into the interior cavity <NUM> of the outer shell <NUM>, such that the inner liner's base <NUM> is positioned adjacent the outer shell's base <NUM>, a portion of the outer shell's interior cavity <NUM>, which can be referred to as an air gap <NUM>, remains disposed between the outer shell's support walls <NUM> and the inner liner's support walls <NUM> and also between the outer shell's base <NUM> and the inner liner's base <NUM>. This air gap <NUM> may be empty, i.e. filled with air, or may be filled with some other material that can prevent or reduce heat transfer from the inner liner's interior cavity <NUM> to the exterior of the outer shell <NUM>. This air gap <NUM> maximizes cooling performance.

In some other exemplary embodiments, the inner liner <NUM> is disposed into the interior cavity <NUM> of the outer shell <NUM>, where at least one of the inner liner's base <NUM> and/or the inner liner's support wall <NUM> is contact with the outer shell's base <NUM> and/or the outer shell's support walls <NUM>. In these embodiments, the inner liner's lip <NUM> is disposed above the outer liner's lip <NUM> and is not in contact with the outer shell's lip <NUM>, thereby defining a space between the inner liner's lip <NUM> and the outer shell's lip <NUM> when the inner liner <NUM> is disposed within the outer shell <NUM>. Further, in some of these embodiments, the inner liner <NUM> may not have a lip <NUM> since the inner liner's lip <NUM> is not needed to rest upon the outer liner's lip <NUM>. In the embodiments described within this paragraph, the air gap <NUM> may or may not be formed between the inner liner's base <NUM> and the outer shell's base <NUM> and or between the inner liner's support walls <NUM> and the out shell's support wall <NUM>.

The cooler <NUM> can further include a lid <NUM> capable of covering or substantially covering the inner liner's opening <NUM>. In this regard, the lid <NUM> can be 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. The lid <NUM> can be shaped in conformity with the inner liner's opening <NUM>, where it rests upon the inner liner's lip <NUM> and inside of the outer shell's vertical lip wall <NUM>. Alternatively, the lid <NUM> may be formed so as to cover and sit atop and around the outer shell's lip <NUM>. According to some embodiments, the lid <NUM> is 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. According to the exemplary embodiment, the lid <NUM> is single-walled and includes an outer wall surface <NUM> and an inner wall surface (not shown); however, in other embodiments, the lid <NUM> may be double-walled. In the present embodiment, the outer wall surface <NUM> can be formed to include various features. For instance, the lid's outer wall surface <NUM> can be formed with one or more cup holders <NUM>. The one or more cup holders <NUM> can be formed into the outer wall surface <NUM> in any suitable configuration. Characteristics such as the dimensions, positioning, and number of the one or more cup holders <NUM> can vary. Further, the lid <NUM> may include two or more centrally formed indentations <NUM> that forms a handle <NUM> that an end-user can use to place the lid <NUM> onto the body <NUM> of the cooler <NUM> or to remove the lid <NUM> from the body <NUM> of the cooler <NUM>.

Notably, the outer shell <NUM>, the inner liner <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, one or more of the above referenced components can be made entirely of a disposable, biodegradable and/or recyclable material, such as a pulp-based material, and one or more of the remaining components 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, any one or more of the outer shell <NUM>, the inner liner <NUM>, and the lid <NUM> can be formed from other disposable, biodegradable and/or recyclable material such as paper, sugar cane, hemp, jute, bamboo, and other similar type materials.

<FIG> shows a cross-sectional view of the double-wall, slip fit cooler <NUM> without the lid <NUM> (<FIG>) in accordance with a second embodiment of the present invention. Referring to <FIG>, the double-wall, slip fit disposable cooler <NUM> will be described in accordance with the second embodiment of the present invention.

The double-walled, slip fit disposable cooler <NUM> includes a body <NUM> and the lid <NUM> (<FIG>). The cooler <NUM> is similar to cooler <NUM> (<FIG>) except for a few differences as discussed herein.

The body <NUM> includes the outer shell <NUM> and an inner liner <NUM>. The outer shell <NUM> of cooler <NUM> is similar to the outer shell <NUM> (<FIG>) of cooler <NUM> (<FIG>) and therefore is not described in further detail herein. The inner liner <NUM> of cooler <NUM> is similar to the inner liner <NUM> (<FIG>) of cooler <NUM> (<FIG>); however, inner liner <NUM> is dimensioned such that when inner liner <NUM> is disposed within outer shell <NUM>, there are no air gaps therebetween and the inner liner <NUM> is in direct contact with the base <NUM> and the plurality of support walls <NUM> of the outer shell <NUM>. The absence of the air gap between the inner liner <NUM> and the outer shell <NUM> maximizes the strength and stability of the cooler <NUM>.

Claim 1:
A double-walled, slip fit disposable cooler (<NUM>, <NUM>) comprising:
a body (<NUM>, <NUM>) comprising:
an outer shell (<NUM>) comprising a base (<NUM>), a plurality of support walls (<NUM>) coupled to the base (<NUM>), and a lip (<NUM>) formed at the distal ends of the support walls (<NUM>) away from the base (<NUM>), the base (<NUM>) and the plurality of support walls (<NUM>) defining an interior cavity (<NUM>) therein; and
an inner liner (<NUM>, <NUM>) comprising a base (<NUM>), a plurality of support walls (<NUM>) coupled to the base (<NUM>), and a lip (<NUM>) extending substantially horizontally from the support walls (<NUM>) at a distal end from the base (<NUM>), the base (<NUM>) and the plurality of support walls (<NUM>) defining an interior cavity (<NUM>) therein and forming an opening (<NUM>) at the upper terminus of the plurality of support walls (<NUM>), wherein the inner liner (<NUM>, <NUM>) is removably disposed within the outer shell (<NUM>) and the inner liner's lip (<NUM>) is set atop of and supported by a portion of the outer shell's lip (<NUM>); and
a lid (<NUM>) substantially covering the opening (<NUM>) of the inner liner (<NUM>, <NUM>)
characterized in that
at least one of the body (<NUM>, <NUM>) and the lid (<NUM>) are made entirely of a disposable,
biodegradable and recyclable pulp-based material.