Patent ID: 12187524

DETAILED DESCRIPTION

The description that follows, and the embodiments described therein, are provided to illustrate examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are substantially to scale, except where noted otherwise, such as in those instances in which proportions may have been exaggerated in order more clearly to depict certain features of the invention.

For the purposes of this description, it may be that a Cartesian frame of reference may be employed. The vertical direction, or z-axis, extends in an up and down orientation from bottom to top. The x-axis extends in the shorter dimension of the container assembly, when fully expanded, running in the front-to-back direction. The y-axis extends cross-wise horizontally relative to the x-axis, running in the side-to-side direction. Unless noted otherwise, the terms “inside” and “outside”, “inwardly” and “outwardly”, refer to location or orientation relative to the associated enclosed space of the container assembly, as may be. The base of the article, where substantially planar, may be considered to extend in an x-y plane. The height of the article may be measured in the vertical, or z-direction. In other contexts, when looking at a single panel, reference may also be made to the “through-thickness” direction or dimension through the wall structure. The largest container panels herein may be designated arbitrarily as either the front and rear sides, walls, faces, or portions of the container. Similarly, the closure member, or opening is arbitrarily designated as being at the top, and the base panel is designated as being at the bottom, as these terms may be appropriate for the customary orientation in which the objects may usually be found, sold, or employed, notwithstanding that the objects may be picked up and placed on one side or another from time to time at the user's choice. It should also be understood that, within the normal range of temperatures to which food and touch is accustomed, although the term cooler, or cooler container, or cooler bag, may be used, such insulated structures may generally also be used to aid in keeping food, beverages, or other objects either warm or hot as well as cool, cold, or frozen. That is, although the term “cooler” may be used for convenience in describing a thermally insulted container, the “cooler” may sometimes be used to keep objects warm rather than cold, e.g., as when hot foods are being transported from a kitchen, or take-out restaurant, to a place where those foods will be eaten some distance away.

The term “insulated” or “insulated wall structure” may be used in this description. It is intended to pertain to walls having a layer of thermal insulation. Typically such walls have an inner surface or lining or web, an outer surface or lining or web, and a layer of insulation material captured between the inner and outer surfaces. The outside layer may be a wear-resistant or scuff resistant material. Thin single membranes or sheets of web material, such as woven high density Nylon™, or Vinyl™, or leather, or paper, are not of themselves intended to fall within the meaning of the term “insulated” as used herein unless they have been treated or formed in an manner deliberately to enhance thermal insulating properties.

Accordingly, the adjective “insulated” is intended to be given its usual and normal meaning as understood by persons skilled in the art. It is not intended to encompass single layers, or skins, of conventional webbing materials, such as Nylon™, woven polyester, canvas, cotton, burlap, leather, paper and so on, that are not otherwise indicated as having, or being relied upon to have, particular properties as effective thermal insulators other than in the context of being provided with heat transfer resistant materials or features beyond that of the ordinary sheet materials in and of themselves. Following fromPhillips v. AWH Corp., this definition provided herein is intended to supplant any dictionary definition, and to prevent interpretation in the US Patent Office (or any other Patent Office) that strays from the customary and ordinary meaning of the term “insulated”. The Applicant also explicitly excludes cellophane, waxed paper, tin foil, paper, or other single use disposable (i.e., not intended to be re-used) materials from the definition of “washable”.

A soft-sided insulated structure is one in which the insulated panels are flexible panels, typically in the form of fabric or plastic sheets with insulation inside. The insulation usually has the form of a flexible open cell or closed cell billet, or slab, which may have been bent or folded or molded into the shape of the wall structure.

A soft-sided insulated structure may be understood as being in contrast to a hard-sided insulated structure in which the insulation is contained within a rigid molded structure, and in which the insulation itself may be substantially rigid. In that regard, too, this description distinguishes of hard-shell containers from soft-sided containers. In the jargon of the trade, a soft-sided cooler, or bag, or container, is one that does not have a substantially rigid, high density exoskeleton. A typical example of a container having a hard exoskeleton is one having a molded shell, e.g., of ABS or polyethylene, or other common types of molded plastic. Rather, a soft-sided container may tend not to be substantially rigid, but may rather have a skin that is flexible, or crushable, or sometimes foldable. By way of an example, which is not intended to be exhaustive, comprehensive, exclusive or limiting, a soft-sided cooler may have an outer skin, a layer of insulation, and an internal skin, both the internal and external skins being of some kind of webbing, be it a woven fabric, a nylon sheet, or some other membrane. The layer of insulation, which may be a sandwich of various components, is typically a flexible or resilient layer, perhaps of a relatively soft and flexible foam.

In some instances, a substantially rigid liner is mounted inside the soft-sided insulated structure to stiffen it. The liner is typically removable, although not always. In some examples, a soft-sided insulated wall structure may include one or more permanent or removable battens or stiffeners (which may be of a relatively hard plastic) concealed within the soft-sided wall structure more generally. Soft-sided insulated containers may have hard molded fittings either at a container rim or lip, or to provide a base or a mounting point for wheels, where the outside of the assembly nonetheless remains predominantly of soft-sided panels. Once again, this commentary is intended to forestall the adoption by the US Patent Office, (or any other Patent Office), of an interpretation of the term “soft-sided” that diverges from the ordinary and customary meaning of the term as understood by persons of ordinary skill in the art in the industry, and as used herein.

As a general overview,FIGS.1ato1c;2a-2i; and3a-3hshow a soft-sided insulated container assembly identified as20. Container assembly20includes a first portion such as may be identified as an outer casing22in the nature of a soft-sided, insulated wall structure which is first or main portion, or main body of container assembly20. Container assembly20also includes a second portion24. Second portion24includes a liner26, a rim or frame28, and a lid or lid assembly30that is hingedly mounted to the upper rearward margin of frame28. Lid assembly30is movable in a first degree of freedom, namely pivotally about a hinge axis, between a first position and a second position, the first position being an open position as seen inFIG.1cand the second position being a closed position generally as seen inFIG.1a.

Outer casing22may be generally box-shaped. That is, it may have a base or bottom panel32, and an upstanding peripheral wall structure34that defines the sidewall of outer casing22and that includes four sides or side panels40,42,44and46, being, respectively, front panel40, rear panel42, left hand side panel44and right hand side panel46. Base or bottom panel32, and the four side panels40,42,44, and46of upstanding peripheral wall structure34may combine to form a five-sided open-topped box. A chamber36is defined within the box, i.e., the upstanding soft-sided insulate wall structure. The respective upper margins of the sides co-operate to define a four-sided opening38of chamber36. In summary, bottom panel32, and side panels40,42,44,46of upstanding peripheral wall structure34co-operate to define a five-sided, open-topped box. As seen, bottom panel32has rounded corners and the respective sides merge into each other on rounded corners having a large radius, as seen from above or below.

In container assembly20, each of panels32,40,42,44and46may tend to be square or rectangular although this need not be so. For example the side panels could be trapezoidal such as to produce a box of tapering dimensions. Bottom panel32may tend to be rectangular, and may typically have two short sides, or edges, and two long sides or edges. The long edges may typically correspond to the front and back sides. The front and rear panels may tend to be the largest, or major, panels of the assembly. In some embodiments the front and back portions or sides or panels may be taller than wide. As shown, the front and rear panels are slightly wider than tall. Container assembly20has a slight taper from bottom to top such that the bottom is slightly narrower than the top of casing22. Casing22has external lifting members identified as handles70. These may have rigid bails, or, as shown, they may have flexible straps with enlarged load spreading hand grips. Lifting handles70in turn lift casing22, which lifts liner24.

In this type of structure, bottom panel32may have a thickened, durable skin48, that may tend to be scuff-resistant, as appropriate for a member whose exterior surface is intended to contact the ground, and that may be subject to wear when slid or dragged along a roughened surface or loaded onto a vehicle bed. This external skin may be molded to have an upturned lip50. The external skin may be waterproof. External skin48may be made of Nylon™, and may have a flexural stiffness greater than other skins or webbing in the structure. External skin48may include molded protrusions in the form of feet, ribs, ridges or protrusions52that stand outwardly and define the ground-contacting interface or surface or footprint of container assembly20. Spaces between the various protrusions52may provide an allowance or accommodation53for straps, such as may be used to secure items to container assembly20during transit. A layer54of open cell or closed cell insulation may overlie external skin48and may extend upwardly beyond the upper marginal edge of rim or lip50. A further skin, or web, or layer56overlies layer54of insulation. Layer56is the inner skin of the bottom panel and may be part of a larger inner skin of outer casing22more generally. It may be made of a nylon sheet. Similarly, the side wall panels have an external skin58, a layer of insulation60, and an internal skin62. External skin58may be made of a sheet or web that is a rubberized skin that is waterproof. External skin58may be thicker than, and more durable than internal skin62(or56), as it is exposed to the wear of everyday use. The bottom margin of external skin58may be welded to the outward, peripherally extending upturned face of lip50, as by RF welding, and this welded interface may follow the radius of the corners. The upper margin of external skin58may be welded to, or folded over and seamed together with the corresponding peripherally extending upper margin of the inner lining, or web, or layer, skin62. Insulation layer60may be made of rectangular (or trapezoidal, as may be) billets corresponding to each of side panels40,42,44,46, or it may be made as a single piece or two-piece wrap-around rectangular sheet64that conforms to the four-sided shape within which it is contained. Sheet64and insulation layer54co-operate to form a bucket-shaped insulation barrier. Similarly, internal skin62may be a continuation of internal skin56of bottom panel32and they may be formed as a pouch or sack that lines the inside of the insulation. The outside of casing22may also include auxiliary features such as external pouches, such as for documents, and which may have waterproof-zippered closures, as at66, and external attachment or securement members or straps or cords, such as represented inFIG.7aby elasticized securement straps68. It may also have lifting points or lifting lugs72to which a shoulder strap may be attached.

Second portion24may be referred to generally as “the liner”. However, it has three major portions or elements, those elements being a main body or main portion that forms the liner26that goes inside upstanding peripheral wall structure34; a bezel or frame28; and a closure assembly or lid30. In the embodiments illustrated, liner26and frame28are formed as a single integrally molded monolith, being a rigid plastic molding or more simply, a rigid liner. Liner26has the form of a bucket or liquid containing vessel74. It has a bottom wall76and an upstanding peripheral sidewall78. Bottom wall76is substantially rectangular, and corresponds generally to the inside and upwardly facing projection of bottom wall32of first portion22. Peripheral sidewall78is also four-sided to correspond to the four sides or edges of bottom wall76. The four sidewall portions being front, rear, left-hand side and right-hand side are identified as82,84,86, and88. They co-operate with bottom wall76to form an open topped box that surrounds an internal space, or cavity or chamber80. In the embodiment shown, each of the sidewalls82,84,86and88has vertical wall reinforcement or stiffening in the nature of respective pairs of flutes or channels90molded into the respective walls. Although the left-hand and right-hand sides of the container are mirror images of each other, in the embodiment shown front wall82is not the same as rear wall84, but rather has a forwardly bulging profile, such that the overall container is somewhat D-shaped.

Bezel or frame28is located at the upper peripheral margin, or rim92, of upstanding peripheral sidewall78of the body of liner26, as opposed to the lower margin of peripheral sidewall78that merges into bottom wall76. Bezel or frame28can be considered a flange of liner26.FIG.3gis a view of a region of the side wall that does not have latches or hinges. In that section, the upper margin, or rim of the inner peripheral sidewall78of liner26is indicated generally as92. In general, rim92can be considered to commence with the upper end94of the upward leg of sidewall78. Upper end94terminates at a shoulder having a peripherally outwardly extending step or shelf96and a predominantly axially extending wall98. Wall98may be, and as shown is, slightly axially upwardly and outwardly tapering on a draft angle. The inward facing surface of wall98defines a land, or engagement surface, that is opposed to seal100of lid assembly30as lid assembly30closes.

In the section ofFIG.3g, axially upward and peripherally outward of wall98is a peripheral sill that has an outward leg102and an upward leg104that terminates at a chamfer106. Chamfer106ends at an axially extending rounded rib108that forms the most axially upward portion of the flange structure and gives a round-edged rim to the overall structure.

Outboard of rib108is a predominantly axially downwardly depending wall, identified as a flange or skirt110. Skirt110may have, and as shown does have, an outward taper toward its tip. The space between the inside face of skirt110and the opposed outside face of upper end94of side wall78is of a size to receive the upper end of sidewall structure34.

At two or more locations around the rim, or periphery, of container assembly20there are releasable securements that permit outer casing22and liner26to be mated together. In known coolers, the internal liner may have been removable, and some removable internal liners have been rigid. Quite often, a rigid internal liner fits very snuggly within the external soft-sided insulated wall structure, and the friction between them may tend to keep them from separating inadvertently, as when inverted; or even intentionally, as when it is desired to remove the liner for cleaning. However, in a fairly large cooler, when the cooler is inverted, for whatever reason, it may not be desirable for the liner to slide out unexpectedly. Alternatively, where the present cooler is lifted by frame28, the relative weight of casing22may tend also to cause casing22to disengage, which may not necessarily be desired. Accordingly, container assembly20has a set of releasable securements indicated generally as120. Each releasable securement includes a first fitting122mounted to casing22, and a second fitting124mounted to liner assembly24. The fittings are designated as first and second, but could as easily be designated as male and female, inner and outer, and so on. The terminology is arbitrary, and is merely intended to indicate that there are two parts that engage and disengage. It is also largely arbitrary whether whichever of the first or male part and second or female part, is on the casing or on the liner.

Looking atFIGS.6a,6band6c, and at the enlarged view of the embodiment ofFIG.5b, first part122has a base112that is mounted to the upper outside region of casing22. In this instance, the set of fittings, i.e., the set of releasable securements120includes a first part122mounted to end or side wall panel44and another such first part122mounted to the opposite end or side wall panel46. In other arrangements first parts122could be mounted to front and rear panels40and42, whether as2of4such parts. The number of such fittings need not be equal on front and back. E.g., there could be2fittings122on the front wall, and one on the back, or two and three, whether on back or front. There could be more than one such fitting on the end or side walls, and, again, the number of fittings need not be equal or symmetrical. Nonetheless, it is convenient for fittings122to be mounted on the respective end walls (i.e., left-and and right-hand panels40,42), for there to be one such fitting on each of those end walls, for those fittings to be symmetrically mounted relative to the central vertical fore-and-aft centerline plane of the container assembly generally, for the fittings to be mounted roughly in the plane of, and above, the likely center of gravity of the unit when it is full, and for the fittings to be place well up on the wall near the top of the rim.

Base112is a footing, or load spreader that mates to the side wall over a relatively large area, as indicated by the oval footprint seen inFIG.6b. An engagement member114stands outwardly proud of base112. Engagement member114may have the form of a catch, or pawl, or stop, or abutment, or finger, or grip, or dog, or tooth, or detent, however it may be termed. In the example shown, the catch126has a generally triangular shape, and a substantial length, where the length may be of the order of 10 times the root thickness of the tooth. The downward facing side116of the dog, or catch, may be relieved, such that it as a slope extending outwardly and downwardly. When formed in this way, the upwardly facing surface118is also sloped outwardly and downwardly, and functions as a cam. The tip of the tooth is indicated as128.

As seen inFIGS.3gand5b, second part124mounts inside skirt110, and has a mating engagement member130that faces inwardly toward wall78. The embodiment of second portion124inFIG.3gis different from the embodiment of second portion124inFIG.5b. InFIG.3gthe upper end is folded over to fit tightly within the rounded inside radius of upper rib108in a sprung interference fit, and which engagement may include and adhesive or bonding agent. InFIG.5b, the underside of rim270has an internal tapered boss, or mandrel286. Second portion124has an uppermost leg or wedge,288, that has a corresponding tapered blind bore that engages mandrel286. The two parts mate in a sprung interference fit. Again, an adhesive or bonding agent may also be used. Furthermore, inFIG.3g, flange180of lid30extends at its outermost tip to overlie rib108. By contrast, inFIG.5b, flange264of lid assembly230lies within, and flush with, the peripheral wall defined by peripheral rim270.

Whether inFIG.3gor5bor10f, the downwardly depending outer leg of first portion124has a tooth, or ridge, or abutment, or dog132than may also have a generally triangular shape with upwardly and inwardly sloping sides134(upper) and136(lower) such that the upper sloped surface is relieved, and so that tip140will ride along the cam surface118during which time skirt110will flex resiliently and deflect locally outward as the insulation material behind panel78permits it to flex locally inward. Tooth132is mounted on a base142of second part124. Base142is formed to conform to the inside contour of skirt110, and, when in place is secured in place as a doubler or reinforcement that locally reinforces skirt110. Base142also has a lower margin144that extends beyond and below the lowermost edge of base142. Lower margin144as rounded corners, and functions as a handle or hand grip. When tip140clears tip128, skirt110and panel78(whether either or both of them) springs back into place, such that surfaces116and136overlap in opposition to each other, preventing disengagement of the respective mating prongs or teeth or dogs, or pawls, and so preventing liner24from sliding out of casing22. When disengagement is desired, the user may grasp handle144with their fingers and flex skirt110outward in a predominantly rotational flexure. This causes tooth132of second member124to be displaced laterally outward, and to disengage from tooth114of first member122. When so engaged, liner24can slide out of casing22. In this way, the releasable securement fittings120function as one-way releasable securements. That is, on installation they are passive, given the cam relationship between tip140and surface134. They are also self-locking, given the relationship of tips128and140, and surfaces116and136which are angled to draw the latch portions more tightly together when loaded. By contrast, unlocking and releasing fittings120requires that active (i.e., not passive) action of the user to release the catch. As may also be noted, the location of the catches is above the bottom marking of skirt110, and so is largely or completely concealed from view.

Moving on to the closures and latches, it may be noted that when one is sitting at the beach, or at a campsite, and so on, it may be convenient to have easy access to the inside of the cooler. In that context, it may be desirable to have an access to the inside of the cooler that is governed by a friction fit. However, in other, perhaps less casual, circumstances it may be desired to have a closure that is less prone to easy release. In some circumstances it may be desirable for that second closure to be active rather than passive, and to be watertight.

As above, second portion24of container assembly20includes a lid, or lid assembly30mated with rim or frame28of liner26. Lid assembly30may be a unitary molded part. Lid assembly30may be, and as shown is, or includes, a rigid plastic molding. Lid assembly30has a frame150that forms a peripheral wall, and that is shaped to correspond to, and to co-operate with frame28. To that end, they have respective mating hinge fittings152,154along their corresponding rear margins. They assemble together and have an axis of rotation about which lid assembly30pivots between first and second, or closed and open, positions relative to frame28, and therefore relative to liner26and chamber80more generally. Frame150is generally rectangular to correspond to frame28. It may have, and in the embodiment illustrated does have, generously radiused corners and an overall D shape in which the rear margin is straight and the front wall, or forwardmost, margin has a bulging, arcuate form.

The molding of lid assembly30may include, and in the embodiment shown does include, a peripheral flange structure160a spanning main portion162, fore-and-aft stiffeners or ribs or reinforcements164that run between the front and rear, and a closure or cover panel166that may be made of a softer material. A layer of insulation168may seat within lid assembly30between spanning main portion162and soft cover panel166.

Looking at the flange structure in section inFIGS.3a-3h, the continuous spanning web sheet170terminates at its margin at a formed complex flange172that has an inwardly formed rib174from which a peripheral flange176extends outward to terminate at cover panel166. Sheet170, rib174and flange176co-operate to form a continuous, generally four-sided box or lid or cap. This cap has a mating and sealing structure that extends about its periphery. The first parts of the mating and sealing structure are a lowermost leg178, and an uppermost leg180. Lowermost leg178extends outwardly from near the lowermost portion of rib174. a distance sufficient to overlie at least a portion of shelf96. Since shelf96and upper portion94of wall78form an angle section, that section is stiff, and shelf96forms a rigid land that intercepts the tip of leg178as lid30closes. Thus the tip of leg178engages, and mates with, shelf96.

Uppermost leg180includes in innermost root or stub, or first leg portion182that extends outwardly, parallel to leg178. First leg portion182and leg178are spaced apart and opposed, thus forming a channel184into which seal100seats. Seal100is an O-ring seal that goes around the entire periphery of lid assembly30in channel184. Seal100is shown in its undeflected uncompressed shape. On closure, seal100first wipes against upright leg of tapered wall98, forming a peripheral contact.

Uppermost leg180has a kink or step186in the axial direction and then a further outward leg or shelf188that overlies the drip lip of the sill102, followed by a further axial leg190that ends in an outward lip192that defines a seat for the outside edge of cover panel166. Cover panel166has a peripheral lip or toe194that fits within the surrounding wall defined by the inner face of upward axial leg190. The outer tip of lip192fits closely within the opening inside rib108. As may be understood, the multiple angles formed in the portions of second, uppermost leg180yield an edge structure that is rigid, having increased flexural stiffness in both the vertical direction and the lateral direction.

The hinge structure is shown in section inFIG.3h. That is, in the rearward portion or rearward margin of lid assembly30, upper leg180is molded to terminate in a set of solid hinge blocks196that have bores198formed therein in which to receive hinge pins156of hinge fittings154of frame150.

The opposed view ofFIG.3fis seen in section through the upper portion of wall panel40of casing22and of the corresponding front portion of frame28and lid30as mated together in the closed position of lid30. The view ofFIG.3fmay be compared with the views through front latch200seen in the closed and latched position or configuration ofFIG.3d, and the corresponding closed and unlatched position ofFIG.3e. In these positions there is a stationary member in the form of a stationary latch keeper202molded into skirt110of frame28. Latch keeper202extends or stands forwardly, outwardly proud of skirt110more generally, and includes at its lowermost margin a downwardly protruding detent in the form of a ridge204. Ridge204is effectively an over-center device. A rebate or channel, or accommodation, or seat206in which to receive the mating or engaging portion of latch200is formed behind (i.e., inwardly of) ridge204.

Latch200includes a moving member in the form of an arm or a latch lever210that has trunnions, or stub axles208that seat in bores148of the forward stationary hinge block158. Hinge block158is formed as an extension of upper leg180in the midst of the forewardmost region of the forward edge of lid assembly30. Lever210has a lobe, or cam,226that engages, or interacts with, the outermost and uppermost rib of frame rim78. Lever210has roots or arms212to which trunnions208(or a continuous hinge pin in place of trunnions208) are (or is) mounted. Arms212extend radially away from the hinge axis of trunnions208. Arms212are joined by a transom, or cross-piece,214, that runs laterally between them, generally parallel to the hinge axis. At the end of arms212there is a cross-wise extending bail216that is formed in an S-shape to yield a downwardmost engagement member or handle or grip218behind which the users fingers may be placed when opening, i.e., releasing, lever210. The upper edge220of bail216defines an engagement member, or finger, or tooth, that engages, and when pressed pushes past, detent ridge204to snap into, and seat in, the channel, or seat, or accommodation206. That is, as lever210moves to swing pivotally downward from the positon ofFIG.3etoward the position ofFIG.3d, it tends to pop or lift seal100out of its passive engagement with the land defined by tapered wall98. However, as lever210continues to move downward toward its end of stroke, edge220encounters detent ridge204. When this happens a further pushing on handle218causes lever210, and, locally, leg180, to stretch or to flex such that edge220rides over detent ridge204, and then snaps into seat206. The latch must be move through the higher energy, stretched or flexed condition before reaching the lower energy, more relaxed condition at rest in seat206, as seen inFIG.3d. When the latch is released, these same steps occur in reverse. Notably, to ride over detent ridge204and sit in seat206, latch200must impost a positive, downward, force on the interface of the lower face of the tip of first leg198against the receiving land of shelf96, thereby securing the closure in an active, energized condition, i.e., in contrast to the passive condition in which resistance to opening of lid assembly30is determined by the friction of the tip of seal100against axial tapered wall98.

In the alternate embodiment ofFIGS.5aand5b, a lid assembly230has a molded spanning member232and an edge flange structure234. As before the edge flange structure starts with a peripheral rib236that is bumped inwardly into chamber80(or, alternatively expressed, as before, the spanning member web or sheet238is bumped outwardly to give more head room inside chamber80when lid assembly230is closed) that extends around the four sided D-shape of lid230more generally. However, the outboard peripheral leg248of rib236does not extend fully to the cover panel. Rather it ends at an intermediate, half-way height, roughly corresponding to the height of the drip channel lip242of molded frame240. Rather than having an O-ring seal channel defined by legs178and180, edge flange structure234has an outwardly extending web244and a re-entrant, or downwardly, extending leg246that runs generally parallel to, and spaced apart from peripheral leg248, and that has a molded peripheral spline252in one or both of its internal walls in legs246and248. A channel250is thereby formed between legs246and248. A further wall or web portion254, which is effectively a continuation of web244, offset upwardly therefrom, extends outwardly to form a shoulder256at the root or base of leg246. A further peripheral leg or peripherally wall260extends upwardly predominantly axially from the outermost edge of web portion254on an outwardly splayed taper. Leg260terminates in a further lateral web262that extends laterally outwardly to a further flange264that extends downwardly in general spaced opposition to leg260. The back or upper end266of flange264extends upwardly proud of lateral web262, thereby defining an internal shoulder268. The outside tip of end266bulges laterally beyond leg264forming a close fit inside peripheral rim270of frame240.

A molded spanning member, or tray,280, has a spanning panel or web, or sheet272, and a peripheral wall274. Peripheral wall274has a folded-over rib portion276, and an extending leg278that protrudes downwardly from the crown of the inwardly facing rib portion276. On installation, the tip of leg278bottoms on the upwardly facing back of leg or flange264, thus establishing the height of sheet272relative to sheet238. The tip of the inside face of wall260and the outside of the tip of the outer leg of rib276are correspondingly notched to fit together, as at282, so that, on installation, tray280snaps into place, and is prevented by the notched relationship from disengaging. These panels may be molded to have a formed profile, or they may be substantially or entirely flat, or formed on a smooth arc. The space between sheet272and sheet238may be filled with insulation168. The space defined inside shoulder268and outside sheet272is filled with a soft cover panel284of such appearance as may be. Cover panel284can alternatively be a herd member presenting a working surface, such as a cutting board. Either or both of tray280and cover panel284may be made of either rigid molded material, or of a soft-sided, fabric material, which may include a layer or batt of insulation.

As seen inFIG.5b, the outside face of leg246is tapered outwardly. A seal is shown as290. The major portion of seal290is a P-seal leg292. It has a root that forms a lateral web294and a leg296that extends upward. Leg296has outside ridges298that fit into splines252. The back of P-seal leg292and leg296sandwich leg246of edge flange structure234. In operation, in the unlatched condition, the bulb of P-seal leg292encounters the taper of wall98, in a passive, friction fit. When latch110is closed, it forces the tip of leg246into web294, which actively energizes the seal.

Container assembly20also has a pressure relief vent,300, which allows the passage of air, but not the passage of liquids. Such a valve or vent prevents the build-up of a pressure differential between inside and outside during normal use, such as may tend to permit container assembly20to be opened more easily, while also maintaining the water-proof nature of the rigid liner and lid combination. Such relief vents are available from commercial vendors. A vent146may be located in the rear wall of container assembly20, for example between the hinges or in the side wall as seen inFIG.10h.

In the embodiment ofFIG.3i, pressure relief vent300has an exterior port302, and interior port304, and a passageway between them defined by a tube306. Interior port302may be molded into the peripheral inward rib of the lid molding, as shown. Exterior port304may likewise be formed in, or may pass through, the external peripheral flange structure, again as shown inFIG.3i. Tube306may be a flexible tube made of a relatively soft rubber or vinyl, having an internal end that mates with interior port302. In the example shown, interior port302is a male stub, and tube306fits over the stub. At the outer end tube306has a collar308that seats inside the vertical leg of the lid. The open end faces the root of the moving member.

When latch lever210is closed, lobe226is brought into engagement with tube306, and, in so engaging, blocks it, the end of the tube being flexible and resilient to form a seal on lobe226. Thus the motion of locking lever210also seals container assembly20. Thus lever210has three positions: locked; passively disengaged such that the lid assembly is held in a friction fit; and fully open, as inFIG.3e.

In an alternate embodiment there is a soft-sided insulated container identified as cooler assembly320, as seen inFIGS.7ato7h. The basic components of cooler assembly320are given the same annotation numbers as the corresponding features of container assembly20. Cooler assembly320, like cooler assembly20is a soft sided insulated container. The wall structure of an outer skin; a layer of insulation; and an inner skin, is as before. Cooler assembly320has a casing322, and a liner324. Liner324includes a main body portion326(which may also be referred to as “the liner”, and that seats inside casing322), a frame assembly328, and a lid assembly330. The hinge structure and arrangement between frame assembly328and lid assembly330may be taken as being substantially the same as that of container assembly20.

Container assembly320differs from container assembly20in being larger.

Accordingly, it is both taller and wider; and rigid liner main body portion326has three flutes90in the front and rear walls, rather than two. Also, given the size, it has two latches400rather than the single latch210of container assembly20. Furthermore, the latch assemblies shown are two-part cam latches as opposed to a single part lever as in container assembly20. Container assembly320also has a different two stage closure and seal from that of container assembly20, whether ofFIGS.3a-3hor ofFIGS.5aand5b.

Considering the latch structure ofFIGS.9aand10a-10d, lid assembly330has a generally rectangular shape when seen from above in plan view. It has an inner surface or skin or panel in the form of a spanning web332that, when closed, forms the roof of chamber350. There is also an outer surface or spanning sheet, or panel or web334.

InFIG.10c, outer web334has spaced-apart reinforcement ribs336that run cross-wise. Insulation, such as foam insulation338may fill the space between webs332and334. Around the periphery of lid assembly330there is a molded structural frame340, which, again, is generally rectangular with radiused corners to follow the plan form shape of lid assembly330, or frame324and of casing322more generally, much as described above. Structural frame340effectively forms a stiffened peripheral margin, or flange structure, around both web332and web334, with segments thereof extending along the respective front, rear, left-hand side and right hand side margins or portions of lid assembly330. Structural frame340differs from structural frame28. In the first instance, because structural frame340is part of the lid assembly, which, of course, moves between open and closed positions; whereas structure frame28is part of the stationary structure of liner24. Lid assembly30has a peripheral edge that closed within, and then lay flush with, frame28. By contrast, in the closed position structural frame340lies over, and forms a visually concordant profile with, frame324.

Structural frame340has a downwardly formed peripheral rib342. It merges into the margin of inner spanning sheet332, with an array of internal form-holding webs or gussets344spaced all around. Rib342transitions into an inward channel or hat section350having an inner leg346, an outer leg348and a back352. Outboard of leg348is a grip in the form of an upwardly molded impression354into which a person's finger tips might fit when opening the container assembly. An outer leg356of frame340extends upwardly from the outside lip of impression354. Outer leg356forms the outside profile of frame340and of lid assembly330more generally. Outer leg356curls around and has an upper portion358that overspans flange354, and is generally opposed thereto and spaced apart therefrom such that portion358functions as a flange in opposition to the web of accommodation354, with leg356functioning as a shear web between them. Inboard of portion358there is a downward chamfer362prior to merging with sheet334. Chamfer362acts as a retainer, or retaining lip to discourage objects from sliding off sheet334. Flange358has a stiffening rib336that acts like a longitudinal stringer.

Rigid frame360of liner324is also different. It has upstanding internal liner wall78, but it terminates in an upper margin formed back on itself into channel section366that nests within channel section350of lid assembly330. The upper end of inner wall78is the first leg of that channel section, and it has an interference friction fit relationship with leg348. The outer leg368extends downwardly to merge into a laterally outwardly extending formed flange370that ultimately has an outermost, downwardly curled web376whose outer leg378lies in the same plane, or the same general arc of curvature, as may be, as the laterally outermost segment or flange portion of outer leg356, to give a relatively smoothly mating relationship or appearance.

As seen inFIG.10c, a seal380locates inside channel or hat section350. Seal350may be, and in the embodiment illustrated is, an O-ring seal that extends about the periphery of frame340. It may be a hollow section seal. That hollow section may be D-shaped, P-shaped, or rectangular, as shown. In operation, when the lid is not latched, there is a passive friction fit engagement as one or other of the outside leg surfaces of the walls of channel section362comes into engagement with the inside wall of one of the side legs of channel or hat section380. There may be passive engagement on seal380. When the latches are closed, there is active engagement that imposes a closing force at the closure interface between the lid frame and the liner frame, which actively energizes, and compresses, seal380under a more-than-gravity load.

Having considered the seal closure interface generally, latches400are shown inFIGS.10a-10d. Latches400are compound latches. A stationary keeper402is formed in frame340, having an upwardly protruding detent or ridge, or catch404. The molded keeper structure is formed in a rebate or accommodation406molded into the front face of frame340such that, when latch400is closed, latch400sits largely or completely within the profile of the adjacent frame structures of lid assembly330and liner frame360.

In this structure, rather than the section seen inFIG.10c, the section in the midst of Accommodation406is seen inFIG.10d. Here the outer profile of frame340has been interrupted, and there is a vertical web408of keeper404that runs between sidewalls382of accommodation406. The recessed wall384slopes outward and downwardly from sheet334. It has a dog-leg folded in to accommodate closing finger440of latch400. Recessed wall384ends in vertical web408. In this section outer leg348of top hat350has an outwardly extending flange394that ends at, and mates with the bottom edge of vertical web408. Similarly, frame360is locally interrupted by accommodation386that has side walls388. In the midst of accommodation386, the section of frame360replaces items376and378with an extended flange390that is an extension of flange370. There is also a vertical web or leg392that runs between side walls388and that forms a T-stem with flange390, making a stiffened section. The outer margin of flange390ends at a downwardly depending web or flange, or retainer, or finger394. When lid assembly330is closed, vertical web408and web392are roughly aligned in a common vertical plane.

Latches400also include a moving assembly420having a first leg422and a second leg424. First leg422is a lever constrained to pivot about a hinge pin426that passes through a stationary boss428centered in latch accommodation430of frame360. Hinge pin426pierces the side walls of boss428and is captured below flange390and behind finger394. In the embodiment shown, first leg422has a pair of spaced apart arms432that straddle boss428. The outermost, or distal, end of first leg422is formed into the shape of a handle or grip434for engagement by the user's fingers or hands more generally. Second leg424is pivotally mounted on a hinge pin438at a location part way along first leg422, roughly the mid-way location as seen inFIG.10a. Second leg424is a grip, or claw, or clasp that is pivotally secured to hinge pin438at one end. It likewise has a pair of arms436that bracket arms432, and a cross-member442that includes a finger440at the distal end furthest away from hinge pin438. Finger440over-reaches and engages detent ridge or catch404. When handle434is pressed downward the hinge pins move through an over-center condition in which they can impose a downward closing force through finger440and into catch404, thus energizing seal380. In this position the U-shaped structure of arms432and the cross-member of grip434of first leg422nests about three sides of boss428, and nests within the U-shaped structure of arms436and cross-member442of second leg424within the profile of frames340and360.

In this configuration, as before, there is a first stage of closure in which the closure is a passive friction fit, and the latch is released. There is also a second mode or stage of closure in which the latch is applied, and a greater-than-gravity active force is applied at the closure interface to energize seal380.

FIG.10fis a section of an alternate releasable securement450of the main casing to the internal liner, whether of casing22or322, and whether the liner is liner assembly24or liner assembly324, seen in contrast to securement120. As before, the first and second portions are indicated as122and124. The components of assembly450are understood to be the same as those of assembly120, unless otherwise noted, and have the same annotation numbers. As in the other views, frame340includes channel section350that houses seal380. Outer leg348terminates in a flange444that extends horizontally outboard above opposed flange390. As before, second portion molded fitting452mounts snuggly within, and has a shape that conforms to, the inside of frame360. Fitting452has an outer skirt or wall454that fits within skirt110; an upper web or back456that mates with the underside of flange390; and an inner wall or flange458that is opposed to, and abuts, the outside face of wall78. In that regard, fitting452has a section seen inFIG.10fof a channel having legs of unequal length, the outer leg being much longer than the inner leg. In this example flange390and back456have mating mate and female engagement fittings460,462. As shown, fitting460of flange390is a male fitting in the form of a downwardly protruding boss. Fitting462of back456is a female socket that receives male fitting460. As stub, or lock, or rivet, or short screw is driven from below into the blind bore of male fitting460, and prevents handle140from disengaging from skirt110.

By contrast to the standard wall section ofFIG.9a, enlarged inFIG.10g, the sectionFIG.10eshows a section through a hinge fitting of the rear of container assembly320, andFIG.10fshows a comparable section other than at the location of a hinge. At the location of the hinge, top hat350has downwardly extending leg464that is shorter than customary leg348, and back352has an extension466that runs outboard to intersect frame340. As shown, back352and extension466are coplanar. In this configuration leg464forms a web or stem or T relative to the flange defined by back352and extension466. Leg464, back352and leg346form the channel in which seal380seats. An internal reinforcement, or gusset,448bridges the space between legs366and378under flange446.

At the location ofFIG.10e, skirt110of frame360has an outer wall468that terminates upwardly in a hinge fitting470, and a back472that runs from hinge fitting470to leg366. Internal gussets474extend between inner wall366and outer wall468, acting as a reinforcement or load spreader that holds the profile of the section. Lid assembly330has corresponding hinge fittings476that depend from extension466to lie in an axially corresponding position to hinge fitting470. A hinge pin478passes between, and connects, fittings470and476. The centerline of hinge pin478defines the pivot axis of lid assembly330.

In the embodiment ofFIGS.11a-11kand12a-12f, there is a soft-sided insulated container assembly500that may be taken as being of the same construction as soft-sided insulated container assembly20or soft-sided insulated container assembly320. It has a soft-sided insulated main body, or casing,502and a rigid liner assembly504, which may be that includes a main tub portion506, which itself has a rim or flange assembly508and a lid assembly510. Casing502and rigid liner assembly504may be understood to be releasably secured by releasable securement assemblies120located on the respective left-hand and right-hand side walls or end walls, as described above. As above, the structure is waterproof, and rigid liner assembly540has a pressure relief vent146which may be installed as indicated above.

As before, main body casing502has a substantially rectangular bottom wall panel520and an upstanding sidewall structure518that has first, second, third, and fourth portions identified as front wall panel522, rear wall panel524, left-hand wall panel526and right-hand wall panel528. The upper portion of sidewall structure518ends in an upper peripheral margin or rim region516to which the first portion122of releasable securement120is mounted.

Flange assembly508has second portion124of releasable securement120mounted thereto.

Similarly, as before, internal rigid liner container vessel, or tub,506has a rigid wall structure having a bottom wall panel530, and an upstanding molded plastic rigid sidewall structure514that includes first, second, third and fourth upstanding wall panels, being front wall panel532, rear wall panel534, left-hand wall panel536, and right-hand wall panel538, those members co-operating with bottom wall panel530to form a five-sided, open-topped liquid containing vessel, the same as, or substantially the same as liner26described above. As before, lid assembly510and frame assembly508are joined along their respective rear margins by hinges, such that a pivot relationship is created, lid assembly510being movable between open and closed positions to govern access of objects to and from an internal chamber540. The hinge fittings may be taken as being the same as previously described.

Soft-sided insulated container assembly500is different from soft-sided insulated container assemblies20and320insofar as the latching relationship is reversed such that the stationary portion is on the frame, and the moving portion is on the lid. That is, there is a latching interface defined by a latching assembly550that includes a stationary latching interface member, identified as an anchor, or hold, or keeper552that is mounted to, or forms part of, frame508; and a movable latching assembly554that is mounted to lid assembly510. Movable latching assembly554includes a first member identified as crank556and a second member, or drag link, identified as clasp558. Crank556is pivotally mounted, or rooted, to a fixed pivot point on lid panel560. In the example shown, crank556has a pair of short swing arms562and a cross-member564that extends between the distal swinging tips of arms562. The toes of the short swing arms562are mounted in double shear connections to the pivot points on lid panel560, between central molded anchor, or block542and left-hand and right-hand laterally outboard blocks544on a pivot axis identified as axle546in the sectional views.

The drag link, or clasp,558also has a pair of left-hand and right-hand spaced-apart arms, or legs566that bracket first member556. Legs566are joined at their distal ends by a cross-member568. Cross-member568terminates in a latch engagement member such as may have the form of a curved finger, or hook,570that, in use, engages keeper552. In that regard, in place of skirt110, the front margin of frame508has skirt512that runs between enlarged molded corner fittings572. Skirt512has the downwardly extending leg574that corresponds to skirt110, but, in addition, it has a forwardly outward spur forming a downward finger or catch576. Catch576is located part way down the face of leg574. The depending tip of catch576is spaced forwardly of leg574such that an accommodation578is formed between leg574and catch576. The near ends, or attached ends, of legs566are pivotally connected to first member556by axle580. Axle580is positioned at an intermediate location radially distant from the pivot axis of axle546, such that the outer or distal portion of cross-member568extends radially beyond the axis of rotation of axle580and form a handle, or grip582that in use acts as a closing lever having a measure of mechanical advantage by virtue of the greater radius. In use, the tip of hook570seats in accommodation578, and hook570clasps catch576.

In use, as first member556rotates counter-clockwise, it tightens second member558onto catch576, and may pass through an over-center condition as latching occurs, thus locking latching assembly550in the closed and locked position, and imposing a positive sealing force on seal380, above and beyond the friction retention of lid assembly510relative to frame assembly508. As may be noted, skirt512has an uninterrupted, clear lateral run between molded corner fittings572. That is, there is no interruption, indentation, cavity, protrusion, boss, or block creating a discontinuity in the latching assembly interface. The clasp and the catch meet along more than half the length. In the embodiment shown, they meet over substantially the entire width between molded corner fittings572. Accordingly, the latching force is spread along the mating of the hook and catch.

To open soft-sided insulated container assembly500, the process is reversed. The user lifts forwardly and outwardly on handle or grip582, to cause it to pass through the over-center condition, thus unlocking latch assembly550. Once hook570is clear of catch576, lid assembly510is in the passively closed condition, in which it is held closed by the passive, zipperless friction retention of the inner rib of the lid assembly against the upper rim of the tub. Latch assembly550may be moved further to a storage position by rotation of first member556in the opposite direction until it stops against abutments586at its rotational end-of-travel limit, after which second member558can be rotted until it seats in the conformal accommodation548defined in lid assembly510. In this position, although hook570is facing upward, legs566are either partially or entirely recessed in accommodation548relative to the level of the main spanning portion584of lid assembly510. In this condition, the movable latch assembly554is stored out of the way, and lid assembly510may be opened and closed by lifting to overcome the frictional fit.

The movable latching assembly554has three positions, or states, or conditions, namely a first position, seen inFIGS.11a,11i,12aand12b, in which it is latched and locked, and holds lid assembly510in a clamped, positive force water-tight closure. It is movable to a second position, seen inFIGS.11e,11h,11j,12cand12d, in which it is unlatched, and released from keeper552, but lid assembly510remains closed in a friction fit condition as a zipperless closure that keeps warm or cold items in an insulated chamber, yet permits easy access merely by lifting lid assembly510; and a third position seen inFIGS.11b,11k,12eand12f, in which latching assembly554is stowed in the recessed position in accommodation548.

Various container body and lid combinations have been shown, or described, or both. The features of the various embodiments may be mixed and matched as may be appropriate without the need for further description of all possible variations, combinations, and permutations of those features.

The principles of the present invention are not limited to these specific examples which are given by way of illustration. It is possible to make other embodiments that employ the principles of the invention and that fall within its spirit and scope of the invention. Since changes in and or additions to the above-described embodiments may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details, but only by a purposive reading of the appended claims.