CN111447854A - Backpack with heat insulation device - Google Patents

Abstract

The present invention provides a thermal insulation device that may include an aperture with a water-tight closure that allows access to a chamber within the thermal insulation device. The closure may help prevent any fluid from leaking into and out of the insulation if the insulation is tipped or in any configuration other than upright. The closure may also prevent any fluid from penetrating the chamber if the insulation is exposed to precipitation, other fluids or immersion in water. The insulation may include a back panel support structure and shoulder straps to allow the device to be carried on the body as a backpack. This configuration creates an insulating chamber that is substantially impermeable to water and other liquids when the closure is sealed.

Description

Insulation Backpack

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to US Application No. 15/845,73, filed December 18, 2017, which is a continuation-in-part of US Application No. 15/451,064, filed March 6, 2017, USA Application No. 15/451,064 is a continuation-in-part of US Application No. 15/261,407 filed on September 9, 2016, and US Application No. 15/261,407 is US Application No. 15/ filed on May 13, 2016 154,626 continuation-in-part application, US Application No. 15/154,626 is a continuation-in-part application of US Application No. 14/831,641, filed August 20, 2015, US Application No. 14/831,641, filed September 8, 2014 A divisional application of filed US Application No. 14/479,607, now US Patent No. 9,139,352, which claims priority to US Application No. 61/937,310, filed February 7, 2014. US Application No. 15/261,407, filed on September 9, 2016, also requires provisional applications, namely US Application No. 62/292,024, filed February 5, 2016, and US Application No. 62/, filed February 24, 2016 299,421, priority to US Application No. 62/299,402, filed February 24, 2016. All of the above applications are fully incorporated herein by reference for any and all non-limiting purposes.

technical field

The present disclosure relates generally to non-rigid portable thermal insulation devices or containers for keeping food and beverages cold or warm, and more particularly to thermal insulation devices with waterproof closures.

Background technique

Coolers are designed to keep food and beverages cooler. The container may be constructed of a rigid material such as metal or plastic or a flexible material such as fabric or foam. Coolers can be designed to improve portability. For example, rigid containers can be designed to incorporate wheels for easy transport, or coolers can be designed in a smaller shape to allow an individual to carry the entire device. Non-rigid containers may be provided with straps and/or handles, and in some cases may be made of lighter weight materials to facilitate movement. Non-rigid coolers for maximum portability can be designed with holes in the top that allow access to the contents of the cooler. The holes can also be provided with closures.

SUMMARY OF THE INVENTION

This Summary provides an introduction to some general concepts related to the present invention in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the invention.

Aspects disclosed herein may relate to thermal insulation having one or more of the following structures: (1) a waterproof enclosure; (2) an outer shell; (3) an inner liner; (4) freely floating within the outer shell and inner insulation between liners; or (5) waterproof storage compartments.

Brief Description of Drawings

The foregoing summary, as well as the following detailed description, may be better understood when considered in conjunction with the accompanying drawings. In the drawings, the same reference numerals refer to the same or like elements throughout the various views where reference numerals appear.

1A illustrates a left front perspective view of an example thermal insulation device according to an aspect of the present disclosure;

FIG. 1B shows a front perspective view of the example thermal insulation device of FIG. 1A without the shoulder straps;

FIG. 2 shows a rear perspective view of the example thermal insulation device of FIG. 1A without the shoulder straps;

FIG. 3A shows a top perspective view of the example thermal insulation device of FIG. 1A without a shoulder strap;

3B shows a top view of a portion of the example thermal insulation device of FIG. 1A;

3C illustrates a portion of an alternate top perspective view of the example thermal insulation of FIG. 1A;

4 illustrates a bottom perspective view of the example thermal insulation device of FIG. 1A;

5A shows a schematic diagram of a cross-sectional view of the example thermal insulation device of FIG. 1A;

5B shows another schematic diagram of an enlarged portion of the cross-sectional view of the example thermal insulation device of FIG. 1A;

FIG. 6 shows an exemplary process flow diagram for forming an insulating device;

7A-7J illustrate an exemplary method of forming an insulating device;

8A and 8B depict perspective views of alternative example thermal insulation.

9 depicts a portion of an exemplary closure and an exemplary test method for determining whether a thermal insulation device retains contents therein.

Figure 10 depicts an example test for determining the strength of a thermal insulation.

Figure 11 shows a front view of another exemplary thermal insulation device.

FIG. 12 shows a side view of the exemplary thermal insulation device of FIG. 11 .

13 shows a front perspective view of an exemplary thermal insulation device in an alternate configuration.

FIG. 14A shows a side cross-sectional view of the exemplary thermal insulation device of FIG. 11 .

Figure 14B shows an enlarged portion of Figure 14A.

FIG. 15 shows a schematic exploded view of an exemplary thermal insulation layer used in the example thermal insulation device of FIG. 11 .

Figure 16A shows a portion of another example thermal insulation device.

16B shows a side view of the example thermal insulation device of FIG. 16A.

17 shows a perspective view of another example thermal insulation device.

FIG. 18 shows a front view of the thermal insulation device of FIG. 17 .

FIG. 19 shows a rear view of the thermal insulation device of FIG. 17 .

FIG. 20 shows a side view of the thermal insulation device of FIG. 17 .

FIG. 21 shows a cross-sectional view of the thermal insulation device of FIG. 17 .

FIG. 22 shows a schematic exploded view of an exemplary thermal insulation layer used in the example thermal insulation device of FIG. 17 .

FIG. 22A shows a front view of an example thermal barrier for use with the example thermal barrier of FIG. 17 .

Figure 23 shows an exemplary test method.

24 illustrates a front view of an example thermal insulation device according to an aspect of the present disclosure;

FIG. 25 shows a side view of the example thermal insulation device of FIG. 24 .

FIG. 26 shows a rear view of the example thermal insulation device of FIG. 24 .

FIG. 27 shows a top view of the example thermal insulation device of FIG. 24 .

FIG. 28 shows a bottom view of the example thermal insulation device of FIG. 24 .

FIG. 29A shows a cross-sectional view of the example thermal insulation device of FIG. 24 .

FIG. 29B shows a portion of a cross-sectional view of the example thermal insulation device of FIG. 24 .

FIG. 30 illustrates an isometric view of an example thermal barrier of the example thermal barrier of FIG. 24 .

Figure 31 shows an alternative embodiment of the inner liner of the thermal insulation device.

Figure 32 shows the thermal insulation of Figure 24 in an open position.

Figure 32A shows an example fabrication method for forming a thermal barrier.

33 shows an example method of securing a handle to a thermal insulation.

Figure 34 shows an exemplary test method.

35A shows a front view of another exemplary thermal insulation device.

Figure 35B shows a side view of the exemplary thermal insulation device of Figure 35A.

Figure 35C shows a rear view of the exemplary thermal insulation device of Figure 35A.

Figure 35D shows a top view of the exemplary thermal insulation device of Figure 35A.

Figure 35E shows a bottom view of the exemplary thermal insulation device of Figure 35A.

Figure 35F shows a cross-sectional view of the exemplary thermal insulation device of Figure 35A.

36A shows a partial cross-sectional view of an exemplary cover.

Figure 36B shows a perspective top view of the exemplary thermal insulation device of Figure 36A.

37 depicts an isometric view of a front portion of a thermal insulation device in accordance with one or more aspects described herein.

38 depicts an isometric view of a back portion of the same thermal insulation device of FIG. 37 in accordance with one or more aspects described herein.

39 depicts a front elevation view of a thermal insulation device in accordance with one or more aspects described herein.

40A depicts a side elevational view of a thermal insulation device in accordance with one or more aspects described herein.

40A depicts a right side elevation view of a thermal insulation device in accordance with one or more aspects described herein.

40B depicts another embodiment of a right side elevational view of a thermal insulation device in accordance with one or more aspects described herein.

41 depicts a left side elevational view of a second side of an insulating device in accordance with one or more aspects described herein.

42 depicts a front view of a rear side of a thermal insulation device in accordance with one or more aspects described herein.

43 schematically depicts a cross-sectional view of a thermal insulation device in accordance with one or more aspects described herein.

44 depicts another isometric view of the thermal insulation device of FIG. 37 in accordance with one or more aspects described herein.

45 depicts an isometric view of another embodiment of a thermal insulation device in accordance with one or more aspects described herein.

46 schematically depicts one embodiment of a gap ring fastener in accordance with one or more aspects described herein.

Detailed ways

In the following description of various examples and components of the present disclosure, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures and structures in which aspects of the present disclosure may be practiced. surroundings. It is to be understood that other structures and environments may be utilized and structural and functional modifications may be made in accordance with the structures and methods specifically described without departing from the scope of the present disclosure.

Additionally, while the terms "front," "rear," "top," "base," "bottom," "side," "forward," and "rearward" may be used in this specification to describe various example features and elements, These terms are used herein for brevity, eg, based on the example orientation shown in the figures or the orientation in conventional use. Nothing in this specification should be construed as requiring a particular three-dimensional or spatial orientation of the structures without departing from the scope of the claims.

1-4 depict an exemplary thermal insulation device 10 that may be configured to keep stored desired contents cold or warm for extended periods of time. The thermal insulation may generally include an outer shell 501 , a closure 301 , an insulating layer 502 and an inner liner 500 . As shown in Figure 3C, the liner 500 forms a chamber or receptacle 504 for receiving the desired contents therein. As shown in FIG. 1A , various handles, straps, and meshes (eg, 210 , 212 , 218 , 224 ) may also be included on the thermal insulation device 10 for carrying, holding, or securing the thermal insulation device 10 .

The thermal insulation device 10 may be configured to keep the desired contents stored in the receptacle 504 cold or warm for an extended period of time. In one example, the thermal barrier 10 may also be designed to retain water inside the interior chamber or receptacle 504, and the thermal barrier 10 may be configured to be "watertight" relative to the outside. In other words, when the closure 301 is in the closed position, the insulation 10 may form a "water tightness" inside the liner 500 and water cannot leak into or from the liner 500 from the outside of the liner 500 The inside of the 500 leaked out.

FIG. 4 depicts a bottom view of the thermal insulation device 10 . As shown in FIG. 4 , the thermal insulation device 10 may include a base 215 and a base support ridge 400 . The base support ridges 400 may provide structural integrity and support for the thermal insulation 10 when the thermal insulation 10 is placed on a surface.

In one example, as shown in FIGS. 3A and 4 , the top of the housing 501 has a first perimeter circumference (T _cir ), and the bottom of the housing 501 has a second perimeter circumference or base perimeter 401 (B _cir ). When folded into a cylinder, the circumference of the top of the housing 501 may be equal to the circumference of the bottom, and B _cir may be equal to T _cir . In one example, both the first circumference and the second circumference may have an elliptical shape to form an elongated or elliptical cylinder. In one example, the top outer layer 501a may have a length of 23.5 inches and a width of 5.5 inches. Therefore, the aspect ratio of the top outer layer 501a may be about 4.3. Additionally, the base 215 may have a length of 20.0 inches and a width of 12.25 inches. Therefore, the aspect ratio of the base 215 is about 1.6. In this instance, the aspect ratio of the upper wall may be greater than the aspect ratio of the base.

In one example, as shown in Figure 5A, an inner layer or liner 500 may be formed from a top liner portion or first liner portion 500a, an inner layer middle portion or second portion 500b, and an inner layer bottom portion 500c. Top liner portion 500a, inner layer middle portion 500b, and inner layer bottom portion 500c are secured together, for example, by welding, to form chamber 504. The chamber 504 may be a "dry bag" or vessel for storing the contents. In one example, after the top liner portion 500a, inner layer middle portion 500b, and inner layer bottom portion 500c are secured or joined together, tape, such as TPU tape, may be placed over the seams that join sections of the chamber 504 above. Thus, the liner 500 may retain liquid within the cavity 504 of the thermal insulation device 10 or may prevent liquid contents from entering the cavity 504 of the thermal insulation device 10 . In one example, as will be described in further detail below, the liner 500 may be suspended in the insulation 10 only by the closure 301 .

Insulation layer 502 may be located between liner 500 and outer shell 501 and may be formed as an insulator to help maintain the internal temperature of receptacle 504 . In one example, insulating layer 502 may be a free-floating layer that is not directly attached to outer shell 501 or liner 500 . The insulating layer 502 may be formed from a first portion 502a and a second portion or base portion 502b. The first portion 502a and the second portion 502b may be formed of insulating foam material, as will be described in further detail below.

The first portion 502a may have a rectangular shape that retains its shape when folded into a cylinder and placed between the liner 500 and the outer shell 501 and when enclosed by the outer shell 501 from above. The insulating layer 502 retains its shape, which results in the insulating device 10 having a substantially elliptical cylindrical shape. Thus, similar to housing 501, the top of insulating layer 502 has a first perimeter circumference, and the bottom of insulating layer 502 has a second perimeter circumference. The first peripheral circumference of the insulating layer 502 may be equal to the second peripheral circumference of the insulating layer 502 .

Base portion 502b may be included to provide additional insulation along thermal insulation 10 at base 215 . The base portion 502b may be formed in an oval shape to close the lower opening 506 formed by the cylindrical shape of the thermal insulation layer 502 .

Additionally, the base portion of the thermal insulation device 10 may include an additional base support layer 505 that increases the thermal insulation and structural integrity of the thermal insulation device 10 . The base support layer 505 may also provide additional protection around the bottom of the thermal insulation device 10 . In one example, the base support layer 505 may be formed of EVA foam. The base support layer 505 may include specific designs, such as logos or names, that may be molded or stamped directly into the material. The base support ridges 400 , which provide structural integrity and support for the insulation 10 , may also be molded or stamped directly into the base support layer 505 . In one example, base support layer 505 and base portion 502b can be separated to facilitate assembly.

The housing 501 may be formed from a top outer or first housing portion 501a, an outer or second housing portion 501b, and a bottom or third housing portion 501c. The housing 501 provides a covering for the thermal insulation device 10 . In one example, the insulating layer 502 can be freely suspended within the housing 501 . However, it is contemplated that any of these layers could be fixed or formed as a one-piece unitary structure. Housing 501 may be configured to support one or more optional handles or straps (eg, 210, 212, 218). In this regard, the housing 501 may also include a plurality of reinforced areas or patches 220 configured to help structurally support optional handles or straps (eg, 210, 212, 218). Handles or straps (eg 210 , 212 , 218 ) and other attachments may be sewn using sutures 222 , however in one example these sutures 222 do not extend through housing 501 into insulation 502 . Rather, these sutures are sewn to patch 220, and patch 220 may be RF welded to housing 501, or attached to the housing by any other method disclosed herein.

As shown in FIG. 5A , the first housing portion 501a may be attached to the second housing portion 501b by suture 510 . However, the first housing portion 501a may be attached to the second housing portion 501b around the entire perimeter of the second housing portion 501b using any known method (eg, polymer welding, stitching, or other adhesive).

Additionally, in one example, the base support layer 505 (which may be formed of EVA foam) may be secured to the bottom or third shell portion 501c by lamination. The second housing portion 501b may be secured to the third housing portion 501c and the base support layer 505 by polymer welding (eg, RF welding), stitching, or adhesive.

The thermal insulation device 10 may include two carrying handles 210 connected to the front side 216 of the thermal insulation device 10 and the rear side 217 of the thermal insulation device 10 . In one particular example, the shoulder straps 218 may be attached via plastic or metal clips to the loops 214 (which are attached to the side handles 212 ) to facilitate carrying the thermal insulation device 10 over the shoulder. The thermal insulation 10 may also include side handles 212 on each end of the cooler. The side handles 212 provide the user with another option for grasping and carrying the thermal insulation.

The handle 210 may also be formed with a slot for receiving the ring 214 near the bottom of the attachment point of the handle to the thermal insulator 10 . Ring 214 may be secured to handle 210 and attachment point 213 by stitching, gluing or polymer welding, and may be used to help secure or tether insulation 10 to another structure such as a vehicle, utensil, camping equipment, etc. or Various items such as keys, water bottles, additional straps, bottle openers, tools, other personal items, etc.

Additionally, as shown in FIG. 2 , webbing formed as loops 507 may be sewn to the strips to form handles 210 on the backside of thermal insulation device 10 . Loop 224 may be used to attach items (eg, safety buckles, dry bags) to insulation 10 . The side handles 212 may also provide the user with another option for securing the thermal insulation device 10 to a structure.

In one example, the carry handle 210, side handles 212, shoulder straps 218, and attachment points 213 may be constructed from nylon webbing. Other materials can include polypropylene, neoprene, polyester, Dyneema, Kevlar, cotton, leather, plastic, rubber, or rope. The carrying handle 210 and side handles 212 may be attached to the housing by stitching, adhesive or polymer welding.

The shoulder straps 218 may be attached to the thermal insulation device 10 at the attachment point 213 . The attachment point 213 may be a strap that also forms a slot for receiving the ring 214 . The loops 214 may provide attachment of the shoulder straps 218 .

In one example, ring 214 can be an acetal D ring. Ring 214 may be plastic, metal, ceramic, glass, alloy, polypropylene, neoprene, polyester, Dyneema and Kevlar fibers, cotton, leather, rubber, or rope. Ring 214 may include other shapes, sizes, and configurations other than a "D" shape. Examples include circular rings, square rings, rectangular rings, triangular rings, or rings with multiple attachment points. Additionally, in addition to the carry handle 210 and side handles 212, pockets or other storage spaces may also be attached to the exterior of the insulation 10.

In one example, closure 301 may be substantially waterproof, or may be a barrier to prevent liquid contents from entering or exiting the thermal insulation. Additionally, the closure 301 may be liquid impermeable, preventing liquid penetration of the thermal insulation 10 in any orientation of the thermal insulation 10 . Keeping the closure 301 in a flat plane can also help provide a watertight seal.

3A-3C depict top views of the thermal insulation device 10 and depict the top outer layer or first housing portion 501a and the closure 301 . The top outer layer 501a depicted in FIG. 3A may be secured to the closure 301 . In one example, the closure 301 can be a waterproof zipper assembly and can achieve a water tightness of 7 psi above atmospheric pressure during testing with compressed air. However, in other examples, the water tightness of the closure 301 may be 5 psi to 9 psi above atmospheric pressure, and in other examples the water tightness of the closure 301 may be 2 psi to 14 psi above atmospheric pressure. The waterproof zipper assembly may include a slider body 303 and a pull tab 302 . FIG. 3B shows an enlarged view of the closure 301 including the bottom stop 304 and the teeth or chain 305 . In one particular example, the waterproof zipper assembly may be constructed of plastic or other non-metallic teeth 305 to prevent injury when removing food or beverages from the interior chamber 504 .

As shown in FIG. 3C , closure 301 is open or unzipped, and apertures 512 formed in outer shell 501 and inner liner 500 are open and expose inner liner 500 and interior chamber 504 . It is contemplated that the closure or seal 301 may include various sealing means in addition to the waterproof zipper assembly depicted in Figures 3A-3C. For example, the inner liner can be sealed using Velcro, snaps, buckles, zippers, excess material folded multiple times to form a seal (such as a roll down seal), seals, metal or plastic clamps, and combinations thereof 500 and shell 501.

Figures 8A and 8B depict another exemplary thermal insulation device 1010 having similar features and functions to the examples discussed above with respect to Figures 1A-5B, wherein like reference numerals refer to the same or similar elements. However, in this example, a loop patch 1015 may be provided at the front of the bag. The loop patch 1015 can be configured to receive various types of items or corresponding sets of hooks that can be placed on various items such as fishing lures, keys, bottle openers, card holders, tools, other personal items etc.) anywhere on the surface. Hoop patch 1015 may include a logo, company name, personalization or other customization. The loop patch 1015 can be formed from a needle loop and can have a high cycle life of over 10,000 closures. Additionally, the loop patch can be washable and UV resistant to prevent discoloration. The loop patch can be selected based on the desired shear strength and peel strength, depending on the type of material to be secured to the thermal insulation 1010 .

Additionally, in the example shown in Figures 8A and 8B, a strip of material 1013 may be provided along the bottom of the bag, which may provide additional strength and reinforcement to the outer shell 1501, and may enhance the aesthetics of the insulation 1010.

An example method of forming thermal insulation device 10 will now be described. A general overview of an exemplary assembly process of thermal insulation device 10 is schematically depicted in FIG. 6 . However, the steps do not necessarily have to be performed in the order described. As shown in step 602, the portions used to form the liner 500, the outer shell 501, and the insulating layer 502 may first be formed or cut to size. In step 604 , the cap assembly 300 may be assembled to the closure 301 . In step 606 , the liner 500 can be formed, and in step 608 , the cap assembly 300 can be welded to the liner 500 . In step 610, housing 501 may be formed. In step 612, the insulating layer 502 can be assembled, and in step 616, the insulating layer 502 can be placed into the liner. Finally, in step 618 , the cap assembly 300 can be secured to the housing 501 .

Referring to step 602, as shown in Figures 7A and 7B, the liner top portion or first liner portion 500a and top outer layer 501a (which form the cap assembly 300) may be formed or cut to size. Figure 7C shows the second or base portion 502b of the insulating layer 502 cut or sized from stock foam. In this example, base portion 502b is cut from stock foam 530 by cutting tool 700 . In one example, cutting tool 700 may be formed in the shape of base portion 502b.

Referring now to step 604 and Figure 7D, top outer layer 501a and top liner portion 500a may be secured to closure 301 to form top cap assembly 300, and top outer layer 501a and top liner portion 500a may be secured in a flat horizontal plane to Closure 301 . Referring to Figures 5A-5B, the top outer layer 501a may be attached to the closure 301 by polymer welding or adhesive. Specifically, as schematically shown in FIG. 5B , the closure 301 may be provided with a first flange 301 a and a second flange 301 b which may form a waterproof zipper tape 306 . The top outer layer 501a may be attached directly to the top surfaces of the first flange 301a and the second flange 301b of the closure 301 . In one example, the first flange 301a and the second flange 301b may be RF welded to the bottom side of the top outer layer 501a. In another example, as shown in FIG. 7E , the top liner portion 500a may be provided with tabs 515 . During assembly, the tabs 515 can help hold the outer strip of the top liner portion 500a in place during assembly and can be removed after the canopy assembly 300 is formed.

In one example, the top liner portion 500a may be attached to the structure of the thermal insulation device 10 as schematically shown in Figure 5B. Specifically, top liner portion 500a may be attached to the bottom of closure 301 . For example, as shown in Figure 5B, the first end 540a and the second end 540b of the top liner portion 500a may be attached to the bottom sides of the first flange 301a and the second flange 301b. Top liner portion 500a and top outer layer 501a may be attached to closure 301 by polymer welding or adhesive. Polymer welding includes both internal and external methods. External or thermal methods may include hot gas welding, hot wedge welding, hot plate welding, infrared welding, and laser welding. Internal methods can include mechanical welding and electromagnetic welding. Mechanical methods may include spine welding, stir welding, vibration welding, and ultrasonic welding. Electromagnetic methods may include resistance welding, implant welding, electrofusion welding, induction welding, dielectric welding, RF (radio frequency) welding, and microwave welding. Welding can be performed in a flat or horizontal plane to maximize the efficiency of the polymer welding to the construction material. Thus, a strong watertight seam can be formed to prevent water or fluid from escaping from or entering the interior chamber 504 .

In a particular example, the polymer welding technique used to connect the top liner portion 500a to the bottom of the closure 301 may include RF welding. RF welding technology provides a waterproof seam that prevents water or any other fluid from penetrating the seam at pressures up to 7psi above atmospheric pressure. Thus, the thermal insulation device 10 can be inverted or immersed in water and prevented from penetrating into or leaking out of the interior cavity 504 formed by the liner 500 . In one example, thermal insulation 10 may be submerged to a depth of about 16 feet underwater before a water leak occurs. However, it is contemplated that this depth may range from about 11 feet to 21 feet or 5 feet to 32 feet before any leakage occurs.

Referring next to step 606 and FIG. 7F, the inner layer intermediate portion 500b may be formed by RF welding. As shown in Figure 7F, the inner layer intermediate portion 500b may be formed from a rectangular sheet of material. The inner layer middle portion 500b may also be secured to the inner layer bottom portion 500c in a subsequent step not shown.

Referring to step 608 and FIGS. 7G and 7H , the inner layer middle portion 500b and inner layer bottom portion 500c may be secured to the cap assembly 300 using an RF welding operation.

Referring to step 610 , the second housing portion 501b and the third housing portion 501c supporting the base support layer 505 may be RF welded to construct the housing 501 for the thermal insulation device 10 . In one example, as schematically shown in Figure 5A, a top outer layer 501a may be sewn to the perimeter of the second housing portion 501b to form the housing 501 of the thermal insulation device. The stitched seam edges of the second shell portion 501b and the top outer layer 501a may be covered with fabric adhesive. This assists in closing or engaging the outer shell 501 around the insulating layer 502 .

Referring to step 612 and FIG. 7I, insulating layer 502 may be constructed. In one example, the first portion 502a of the insulating layer 502 can be formed in a rectangular shape and can be secured on the smaller side of the rectangle using double-sided tape to form a cylindrical shape. The second portion or base portion 502b may be formed in an elliptical shape, which may have a smaller circumference than the circumference of the cylindrical shape of the first portion 502a. The second portion 502b may also be secured to the first portion 502a using double-sided tape to form the insulating layer 502 . In one example, double-sided tape may be placed around the inner perimeter of the cylinder of the first portion 502a or around the outer perimeter of the base portion 502b, and the base 502b may be adhered to the first portion 502a. Other methods of securing the base portion 502b to the first portion 502a to form the insulating layer 502 are also contemplated, such as adhesive or polymer welding.

Referring to step 614 , the assembled thermal insulation layer 502 may be placed into the housing 501 . In step 616 , the formed liner 500 and cap assembly 300 may be placed into the insulating layer 502 .

Finally, in step 618, cap assembly 300 may be sewn to housing 501 to form seam 520, as schematically depicted in Figure 5A. In this way, neither the inner liner 500 nor the outer shell 501 need be bonded to the insulating layer 502 . In addition, the liner 500 is only connected to the closure 301, and the closure 301 holds the liner and the outer shell 501 together, which makes the manufacturing process simpler. After the cap assembly 300 is sewn to the shell 501, fabric bond is added to cover the raw edges near seam 520. Accordingly, top seam 520 may be the primary seam on insulation 10 that is formed by sewing only.

In one particular example, the inner liner 500 and the outer shell 501 may be constructed of double-laminated TPU nylon fabric. Nylon fabric can be used as the base material for the inner liner 500 and outer shell 501 and can be coated with a TPU laminate on each side of the fabric. The TPU nylon fabric used in one particular example is 0.6 mm thick, is water resistant, and has antimicrobial additives that meet all FDA requirements. However, it is conceivable that the fabrics used to construct the insulation contain antimicrobial substances to create a mildew-free environment that is safe for food contact surfaces. In a specific example, the nylon can be 840d nylon with TPU. Alternative materials for making the inner shell or chamber 504 and outer shell 501 include PVC, TPU coated nylon, coated fabrics, and other weldable and waterproof fabrics.

Closed cell foam may be used to form the insulating layer 502 between the inner liner 500 and the outer shell 501 . In one example, the insulating layer 502 is 1.0 inches thick. In one example, the insulating layer 502 may be formed of an NBR/PVC blend or any other suitable blend. The thermal conductivity of the example insulating layer 502 may be in the range of 0.16-0.32 BTU.in/(hour·sqft·°F), and the density of the insulation layer 502 may be in the range of 0.9 to 5 lbs/ft ³ . In one example, the thermal conductivity of the insulating layer 502 may be in the range of 0.25 BTU.in/(hour·sqft·°F), and the density of the insulating layer 502 may be 3.5 lbs/ft ³ .

Foam bases can be made from NBR/PVC blends or any other suitable blends. In addition to the base portion 502b of the insulating layer 502, the insulating device 10 may also include an outer base support layer 505 constructed of foam, plastic, metal, or other materials. In one example, the base portion 502b can be separated from the base support layer. In one example, the base portion 502b is 1.5 inches thick. Additionally, as shown in Figure 5A, the EVA foam base support layer 505 may be 0.2 inches thick. Although the base support layer 505 is laminated to the base outer layer or third housing portion 501c, in alternative examples, the base support layer 505 may be attached by co-molding, polymer welding, adhesives, or any known method to the bottom of the base portion 502b.

Heat gain testing was conducted on the exemplary thermal insulation device 10 . The purpose of the heat gain test is to determine how long the insulator can keep the temperature below 50°F in an environment of 106°F ± 4, where the amount of ice depends on the insulator's internal capacity.

The process is as follows:

1. Turn on the oven and set to 106°F ±4. Let the oven stabilize for at least an hour.

2. Open the chart recorder. The logger should have three J-type thermocouples connected to graph the following temperatures: (1) the test cell, (2) the oven, and (3) the room environment.

3. Stabilize the test cell by filling it to half its capacity with ice water and allow to stand at room temperature (72°F ± 2) for 5 minutes.

After 4.5 minutes, the contents were poured out and the J-type thermocouple tip was immediately attached to the inner bottom center of the cell. The ends of the thermocouple wires must be flush with the inner bottom surface and secured with adhesive masking tape.

5. Pour just the right amount of ice to make sure the thermocouple wires don't move. The amount of ice is 4 pounds per cubic foot in terms of the internal capacity of the unit.

6. Close the lid and place the test unit inside the oven.

7. Close the oven and make sure the thermocouple wires are working properly.

8. Mark the start of the chart recorder.

Equipment: 1. Oven 2. Ice 3. Chart recorder 4. Type J thermocouple (3). Results: 1. Cold Hold Time: Elapsed time from <32°F to 50°F in decimal hours. 2. Heat gain rate (°F/Hr): (50°F-32°F) ÷ actual time = 18°F ÷ actual time

In one test of the example insulation, assuming a capacity of 26.5 quarts and testing with 3.542 pounds of ice, the heat gain rate was equal to 1.4 degF/hr.

The ability of the thermal insulation device 10 to withstand internal leaks can also be tested to see how well the thermal insulation device holds the contents stored in the storage compartment or receptacle 504 . In one example test, thermal insulation 10 may be filled with a liquid, such as water, and then inverted for a predetermined period of time to test for moisture leakage. In this example, the insulation 10 is filled with liquid until approximately half the volume of the receptacle 504 is filled (eg, 3 gallons of water), then the closure 301 is fully closed to ensure that the slider body 303 is completely sealed to the horseshoe shape section 308. The entire thermal barrier 10 is then inverted and held upside down for a period of 30 minutes. The insulation 10 is then checked for any leaks.

The thermal insulation device 10 may be configured to remain upside down for 30 minutes without any water escaping or leaving the receptacle 504 . In an alternate example, the thermal barrier may be configured to remain inverted for 15 to 120 minutes without any water escaping or leaving the receptacle 504 . To perform this test, it may be helpful to lubricate the closure to ensure adequate sealing of the closure. For example, as shown in FIG. 9 , the horseshoe portion 308 of the closure 301 is provided with a lubricant 309 .

The fabrics forming the outer shell 501, inner liner 500, and insulating layer 502 of the thermal insulation device 10 can also be tested for strength and durability. In one example, the test can be designed as a puncture test. Specifically, the test can be designed as the ASTM D751-06 Sec. 22-25 screwdriver puncture test. In one example, the thermal insulation device 10 can withstand a puncture force of 35 pounds to 100 pounds.

Insulation 10 can also be tested for handle strength and durability. One such example test is depicted in Figure 10. As depicted in Figure 10, the closure 310 can be fully closed, one of the handles 210 can be hooked to the overhead crane 600, and the opposite handle 210 can be hooked to the platform 650, which can bear the weight. In one example, platform 650 may be configured to support 200 pounds of weight. During the test, the crane 600 was slowly raised, which suspended the thermal insulation device 10 in a position where the bottom plane of the thermal insulation device 10 was perpendicular to the floor. In one example, thermal insulation 10 may be configured to withstand a weight of 200 pounds for at least 3 minutes without showing any signs of failure. In an alternate example, the thermal insulation may be configured to withstand a weight of 100 to 300 pounds for 1 to 10 minutes without showing any signs of failure.

Another example thermal insulation device 2010 is shown in FIGS. 11-15 . The example insulation 2010 may have a similar construction to the examples above, wherein like reference numerals refer to like features with like functions. However, the example insulation 2010 may also include a lower folded flap or portion 2307 to help insulate the closure 2311 of the insulation 2010. In particular, according to other examples discussed herein, closure 2311 (which may be a zipper) may be included on lower folded flap or portion 2307 and may face forward due to its location on the front surface or front wall of insulation 2010. The forward facing closure 2311 may allow the user to otherwise access the insulation 2010, and the lower folded flap or portion 2307 may help provide additional insulation at the closure 2311. In this example, when the lower folded flap 2307 is in the expanded position and the closure 2311 is opened or unsealed, the contents of the insulation 2010 hold the closure 2311 in the open position for better access to the contents of the insulation 2010 thing. This may help the user to more easily access the contents of the thermal insulation device 2010 . As also shown in FIG. 11 , when the lower folded flap 2307 is in the expanded position, the insulator 2010 may be approximately trapezoidal in shape to provide an elongated closure on top of the insulator 2010 .

As shown in the side and cross-sectional views, ie, as shown in Figures 12 and 14A, the insulation 2010 may be approximately pentagonal when the lower folded flaps 2307 of the insulation 2010 are in the expanded position. This general shape can provide insulation 2010 that can be easily shipped because several insulations can be packed into a container. However, other shapes and configurations are conceivable, such as square, rectangular, triangular, conical, curved, and truncated, which can provide an expanded closure on top of the insulator 2010 and which can be easily Package.

Similar to the example above, thermal insulation 2010 may include an outer shell 2501 , a liner 2500 forming a storage compartment, a receptacle, or interior cavity 2504 , and an insulation layer 2502 between the outer shell 2501 and the liner 2500 . Insulation layer 2502 provides insulation for storage compartment 2504. Closure 2311 may be configured to substantially seal opening 2512 located on the angled forward-facing surface and extending through housing 2501 and liner 2500 to provide access to storage compartment 2504. Also, closure 2311 may include similar features and functions in accordance with the examples discussed above. In one example, the closure 2311 can be a zipper and can be substantially waterproof to prevent liquid from flowing out of the opening when the insulation 2010 is in any orientation. Also, similar to the examples above, the thermal insulation device 2010 may be provided with one or more of the following structures: a handle 2210; shoulder straps 2218; webbing loops 2224 formed by stitching, for example, with stitching 2222; loops 2214; and an attachment point 2213, which may have similar features and functions as in the examples above.

As shown in FIGS. 11 and 12 and as described above, the lower folded flap 2307 may include a forward facing closure 2311 and may be folded and secured to the sidewall of the insulation 2010 to further isolate the forward facing closure 2311 hot. The lower folded flap 2307 of the fastening mechanism 2301 may include a first end hook or clip 2313a and a second end hook or clip 2313b. In one example, each of the end clips 2313a, 2313b can include a slot 2317a, 2317b for receipt in a corresponding loop 2315a, 2315b on a side or sidewall of the thermal insulation device 2010. To close the insulation 2010, the lower folded flap 2307 is folded, along with the forward facing closure 2311, onto the front or front wall of the insulation 2010. The lower fold flap 2307 folds over and hides or covers the forward facing closure 2311. The lower folded flap 2307 is held in place by the first end clip 2313a and the second end clip 2313b and holds the fastening mechanism 2301 in the closed position. Additionally, when the lower folded portion 2307 is secured to the sidewall of the thermal insulation device 2010, the lower folded portion 2307 extends at least partially in a substantially horizontal direction, which orients the handle 2318 in a position for grasping by a user for grasping and Carry thermal insulation 2010. As in other handles and straps, the carry handle 2318 may be secured to the housing by reinforcing patches (not shown). A handle 2318 may be provided on the rear surface of the thermal insulation 2010 opposite the closure 2311 on the front facing surface, which handle 2318 may be grasped by the user during opening and closing of the thermal insulation 2010, thereby This makes it easier for the user to open and close the closure 2311 . The carrying handle 2318 may also be used to hang the insulator 2010, or to carry the insulator 2010, although other uses are contemplated.

FIG. 14A shows a cross-sectional side view of thermal insulation device 2010 . The thermal insulation device 2010 includes an inner liner 2500 , a thermal insulation layer 2502 and an outer shell 2501 . As shown in Figure 14A, similar to the examples above, an insulating layer 2502 may be located between the liner 2500 and the outer shell 2501, and may be formed as a foam insulation to help maintain acceptance of the contents for storage of desired cold or thermal insulation the internal temperature of the device 2504. The insulating layer 2502 may also be located between the liner 2500 and the outer shell 2501 , and may not be attached to the inner liner 2500 or the outer shell 2501 such that it floats between the inner liner 2500 and the outer shell 2501 . In one example, the liner 2500 and the outer shell 2501 can be attached at the top portion of the insulation 2010 so that the insulation layer 2502 can float freely in the pocket formed by the inner liner 2500 and the outer shell 2501 .

In this example, the inner layer or liner 2500 may be formed from a first liner sidewall portion 2500a and a bottom liner portion 2500b. The first liner sidewall portion 2500a and the bottom liner portion 2500b may be secured together to form the cavity 2504, eg, by welding. Similar to the examples above, the chamber 2504 may be a "dry bag" or vessel for storing the contents. In one example, after the first liner sidewall portion 2500a and the bottom liner portion 2500b are secured or joined together, a tape, such as a TPU tape, may be placed over the seams that join the sections of the chamber 2504 . The tape seals the seam formed between the first liner sidewall portion 2500a and the bottom liner portion 2500b to provide an additional barrier to preventing liquid from entering or exiting the chamber 2504. Thus, the liner 2500 may retain liquid within the cavity 2504 of the thermal insulation device 2010 or may prevent liquid contents from entering the cavity 2504 of the thermal insulation device 2010. However, it is also contemplated that the liner 2504 could be formed as a one-piece unitary structure that could be secured within the outer shell.

As shown in FIGS. 14A and 15 , the insulating layer 2502 may be formed from a first or upper portion 2502a , a second or base portion 2502b , and a base support layer 2505 . Additionally, the first portion 2502a may include a top flap or a smaller rectangular shape 2502a1. When the lower folded flap 2307 is folded onto the top portion of the thermal insulation device 2010, the top flap 2502a1 of the thermal insulation layer along with the remainder of the first portion 2502a and the base portion 2502b thermally surrounds substantially the entire interior cavity 2504 , to provide the maximum amount of thermal insulation to the interior chamber 2504 of the thermal insulation device 2010.

When the upper portion 2502a is flattened, the upper portion 2502a of the insulating layer 2502 generally resembles a "T" shape such that the insulating layer defines a first height H ₁ and a second height H ₂ , wherein the first height H ₁ is greater than the second height H 1 height H ₂ . In this example, a substantial portion of the insulating layer may extend to a second height H ₂ that is less than the first height H ₁ . Likewise, the first portion 2502a may be formed from two interconnected rectangular shapes, with the bottom portion of the first portion 2502a forming the first larger rectangular shape 2502a2 and the upper section of the first portion 2502a forming the smaller rectangular shaped top flap 2502a1. It is also contemplated that the first larger rectangular shape 2502a2 may be formed as a separate piece from the smaller rectangular shape 2502a1. The first rectangular shape 2502a2 can have a first rectangular width, and the second rectangular shape 2502a1 can have a second rectangular perimeter, and the first rectangular shape 2502a2 has a width that approximates the second rectangular shape 2502a1 perimeter. In one example, the smaller rectangular shape 2502a1 forms the top flap of the insulation of the upper portion 2502a that extends into the lower folded portion 2307.

The first portion 2502a and the second portion 2502b may be formed from the insulating foam materials discussed herein. In one example, the second portion 2502b may be formed of a thicker foam material than the first portion 2502a. For example, the thickness of the second portion 2502b may be formed between 20mm and 50mm thick, and in one particular example, may be formed of 38mm thick foam, while the first portion 2502a may be formed between 15mm and 30mm, and in a particular example In an example, it may be formed from 25mm thick foam. In one example, the foam may be an NBR/PVC hybrid foam, PVC-free NBR foam, or other environmentally friendly foam.

15, the base support layer 2505 increases the thermal insulation and structural integrity of the thermal insulation device 2010 at the base 2215. The base support layer 2505 may also provide additional protection around the bottom of the thermal insulation device 2010. In one example, the base support layer 2505 may be formed of EVA foam. The base support layer 2505 may include specific designs, such as logos or names, that may be molded or stamped directly into the material. The base support ridges 2400 that provide structural integrity and support to the insulation 2010 can also be molded or stamped directly into the base support layer 2505. In one example, to facilitate assembly, the base support layer 2505 and base portion 2502b may be separated or unsecured, thereby reducing the number of assembly steps. The base portion 2502b may be formed in an oval shape to close the lower opening 2506 formed by the open shape of the upper portion 2502a.

When folded into an elliptical cylindrical shape and placed between the liner 2500 and the outer shell 2501, the bottom of the first portion 2502a retains its shape. The insulating layer 2502 retains its shape, which results in the insulating device 2010 having a substantially elliptical cylindrical shape.

The housing 2501 may be formed of an upper side wall portion 2501a, a lower side wall portion 2501b, and a base portion 2501c. The upper side wall portion 2501a, the lower side wall portion 2501b and the base portion 2501c may be fixed by sewing. Other fixing methods are also contemplated, such as the use of welding or adhesives.

Additionally, the lower folded portion 2307 may be at least partially free of foam to make closing the fastening mechanism 2301 easier. Specifically, the lower folded portion 2307 may include a first section 2307a and a second section 2307b. The first section 2307a may be free of the insulating layer 2502, while the second section may include the insulating layer 2502.

Referring to Figure 14B, similar to the examples above, the closure 2311 may be mounted on a backing or fabric. Where the closure is a zipper, the backing or fabric may be referred to as zipper tape 2306. Also, similar to the example above, zipper tape 2306 may be attached between liner 2500 and outer shell 2501, and in particular, zipper tape 2306 may be secured to upper sidewall portion 2501a and first liner sidewall portion 2500a of the outer shell. As shown in Figure 14B, the zipper tape 2306, the upper sidewall portion 2501a of the outer shell, and the first liner sidewall portion 2500a may form a stacked arrangement of a sandwich structure, with the zipper tape 2306 between the upper sidewall portion 2501a of the outer shell and the first inner sidewall portion 2500a. Lining between the sidewall portions 2500a.

Thermal insulation 2010 may be formed using similar techniques in relation to the examples discussed above. For example, the upper side wall portion 2501a of the housing 2501 may be formed. Also, the base 2215 may be formed separately from the base portion 2502b of the insulating layer 2502, the base support layer 2505, the lower sidewall portion 2501b, and the base portion 2501c of the housing 2501, according to the techniques discussed herein. The base 2215 can be secured to the bottom of the upper sidewall portion 2501a of the housing 2501 using the techniques discussed herein. The upper portion 2502a of the insulating layer 2502 may be placed within the upper sidewall portion 2501a of the housing 2501 . The first liner sidewall portion 2500a and bottom liner portion 2500b can then be secured to form the liner 2500 and the cavity 2504. A tape, such as a TPU tape, may be placed over the seams joining the sections of the liner 2500 and the chamber 2504 . The liner 2500 can then be placed within the insulating layer 2502. A closure 2311 can then be attached between the liner sidewall portion 2500a and the upper sidewall portion 2501a. At this point in the process, the insulator 2010 assembly will have a cylindrical shape with an open top. To close the open top, the upper ends of the liner sidewall portion 2500a and the upper sidewall portion 2501a may then be secured together by welding or by using any of the techniques discussed herein to form the insulator 2010 . Adhesive 2518 may be applied to the top portion of insulation 2010 to cover and hide the seam between outer shell 2501 and inner liner 2500. After the shell is formed or once the insulation 2010 is formed, the loop patch (not shown), handle 2210, shoulder straps 2218, webbing loops 2224, and loops 2214 may be added to the Housing 2501. It is contemplated that the inner and outer liners may be formed by welding, gluing, or sewing, and combinations thereof.

In another example, a magnetic connection may be implemented to secure the lower folded portion 2307 to the body of the thermal insulator 2010. As shown in FIGS. 16A and 16B , the thermal insulation device 2010 may be provided with magnetic clamps 3313 that may be received by corresponding magnets (not shown) on the side walls of the thermal insulation device 2010 . However, it is also contemplated that the clips and clip-receiving portions on the thermal insulation device 2010 may be one or more of permanent magnets, metal strips, or ferromagnetic materials. Additionally, other methods of securing the lower fold flap 2307 over the forward facing closure 2311 are also contemplated. For example, one or more of hooks and loops, buckles, snaps, zippers, detents, spring-loaded detents, buttons, cams, or stitches may be used to secure the lower fold flaps 2307 to the insulator 2010 side wall.

17-22 illustrate another exemplary thermal insulation device 4010. The example thermal insulation 4010 may have a similar construction to the examples above, in particular the examples discussed above with respect to FIGS. 11-16B , wherein like reference numerals denote like features having the same or similar functions. In this example, insulator 4010 does not include lower folded flaps, and may include a different overall shape than example insulator 2010 . Additionally, the insulating layer 4502 may have different configurations as well as other variations to be discussed below. Similar to the example above, closure 4311 may be placed on the front or front wall of thermal insulation 4010 .

As shown in FIGS. 18 and 19 , the insulator 4010 can generally form a trapezoidal shape when viewed from the front and rear, with the insulator 4010 offset or tapered upwardly toward the top of the insulator 4010 . The trapezoidal shape may provide certain thermal insulation, user accessibility and packaging benefits. For example, the trapezoidal shape can provide extended ice coverage time because the trapezoidal shape can place additional foam between the outer shell 4501 and the inner liner 4500.

Additionally, the overall shape of the thermal barrier 4010 may help maintain the thermal barrier 4010 in the open position when the closure 4311 is in the open position and provides a user with easy access to the contents of the thermal barrier 4010. The trapezoidal shape, as discussed herein, also allows closure 4311 to be formed longer relative to insulation 4010. Other shapes that allow for expanded openings at the upper portion of insulator 4010 are also contemplated. For example, the upper portion of the insulation 4010 may be formed with a curvature that expands upward or downward to allow a larger closure to extend across the upper portion of the insulation 4010. As also shown in FIG. 20 , the insulator 4010 may be formed to be generally conical, conical, or funnel-shaped when viewed from the side, such that the sides converge to the top of the insulator 4010 . In some instances, the sides may also be formed in a substantially parabolic shape. Thus, the insulator 4010 converges to the apex along the top of the insulator 4010, as opposed to the oval shape where the bottom of the insulator 4010 has the same perimeter.

In some instances, the trapezoidal shape can also provide insulation 4010 that can be easily shipped, as several insulation 4010 can be packed into a container. For example, multiple thermal insulation devices 4010 may be arranged in a container in different orientations to utilize more space within the container.

In an alternate embodiment, the contents of the thermal insulation device 4010 may hold the closure member 4311 in the open position when the closure member 4311 is in the open or unsealed position for easier access to the contents of the thermal insulation device 4010. In this example, the weight of the contents may force the lower half of the closure 4311 away from the upper half of the closure 4311, allowing the user to better see the contents of the insulation device 4010 and to remove the contents more easily or add contents to the thermal insulation device 4010.

In this example, the outer shell construction, thermal insulation layer, and liner construction may be similar to those of the embodiments discussed above with respect to FIGS. 11-16B and the details are not repeated here. The housing 4010 may also include a top portion 4316 configured to receive the closure 4311 therein. The top portion 4316 may be formed of the same material as the rest of the housing 4501, which in one particular example may be nylon, specifically 840d nylon with TPU.

Similar to the examples discussed with respect to FIGS. 11-16B , thermal insulation 4010 may be provided with one or more of the following structures: carrying handle 4210; shoulder straps 4218; webbing loops 4224 formed from stitches 4222; ring 4214; and attachment points 4213, which may have similar features and functions as in the examples above. Additionally, a rear handle 4318 can be provided on the rear surface of the thermal insulation 4010 opposite the closure 4311, which can be used to be grasped by the user during opening and closing of the thermal insulation 4010, thereby allowing It is easier for the user to open and close the closure 4311. The rear handle 4318 can also be used to hang the insulator 4010 to dry the interior chamber 4504, or to carry the insulator 4010. Each of the handle 4210, shoulder straps 4218, webbing loops 4224, and attachment points 4213 may be reinforced by one or more of additional structures in the form of webbing or suitable polymeric materials. The reinforcement material can be applied to any of the examples discussed herein.

Additionally, as shown in FIGS. 17 and 21 , an adhesive 4518 extending over the top of the insulator 4010 may be included to secure the outer shell 4501 to the liner 4500 . Adhesive 4518 may be folded over the top of insulation 4010 and then sewn over outer shell 4501 and inner liner 4500 to form a covering for the joint or seam between inner liner 4500 and outer shell 4501 . As shown in Figure 18, the adhesive 4518 can be folded into three parts to form a first folded portion 4518a, with the first third attached to the first side of the insulator 4010 and the second third attached to the first side of the insulator 4010 The top of the insulator 4010 extends above, while the last third is attached to the second side of the insulator 4010 . Adhesive 4518 covers the seam between outer shell 4501 and liner 4500 along the top of insulation 4010. 17, adhesive 4518 extends from the top of insulator 4010 and forms a second folded portion 4518b (where adhesive 4518 is folded in half) and a third unfolded portion 4518c, which Attachment points 4213 that receive ring 4214 are formed and extend to these attachment points. Each side of the insulator 4010 may include a second folded portion 4518b and a third unfolded portion 4518c, such that the insulator 4010 may include two second folded portions 4518b and two third unfolded portions 4518c. Adhesive 4518 may be deployed closer to attachment point 4213, and may also be formed to be deployed from attachment point 4213 toward the top of insulator 4010. In any of these configurations, a section of adhesive 4518 (eg, second folded portion 4518b ) may not be attached to insulator 4010 and form a strip between folded portion 4518a and attachment point 4213 bring. In this example, two straps can be formed from two second unfolded portions 4518b and can be grasped by a user to manipulate the thermal insulation, can be used to suspend the thermal insulation 4010 for drying, and the like. Likewise, the attachment points 4213 formed by the bond 4518 may be loops or slots for receiving the ring 4214.

Figures 22 and 22A illustrate in greater detail an insulating layer 4502, which is similar to the example insulating device 4010 discussed above, wherein like reference numbers refer to like components having the same or similar functions. The insulating layer 4502 may be formed from the materials discussed herein, and in some instances, may be PVC-free and/or may have non-thermoset properties such that the foam is fully elastic. Similar to the example above, the upper portion 4502a of the insulating layer 4502 may be formed from a single sheet of material that is rolled into the shape defined by the opening between the liner 4500 and the outer shell 4501 . As shown in FIG. 22, as in the examples above, the insulating layer 4502 may be formed from a first or upper portion 4502a and a second or base portion 4502b. The rear top flap 4502a1 may be formed in a smaller rectangular shape. The rear top flap 4502a1 extends higher than the front side of the first portion 4502a of the insulation layer 4502 to accommodate the forward facing closure 4311. Specifically, the rear top flap 4502a1 may extend to a first height H3, while the first portion _4502a may extend to a second height _H4 , and the first height H3 may be greater _than the second height H4 _. Additionally, as shown in FIG. 22, a substantial portion of the insulating layer 4502 may extend to the second height H4 _. Alternatively, as shown in FIG. 22A, the second half of the insulating layer 4502 may extend to the first height _H3 , and the front half of the insulating layer 4502 may extend to the second height H4 _. Additionally, as shown in FIG. 22A, the insulating layer 4502 can be reduced from a first height _H3 to a second height H4 _. Again, this provides a tapered or chamfered portion of the insulation layer 4502 near the top along the sides of the insulation 4010 to provide a smaller profile on each side of the insulation 4010.

In one example, the first portion 4502a can define a first area A ₁ and the rear top flap 4502a1 can define a second area A ₂ that is smaller than the first area A ₁ . When installed between the liner 4500 and the outer shell 4501, the insulating layer 4502 generally follows the conical and trapezoidal shapes of the profile of the insulating device 4010. Additionally, the upwardly tapered contours of the outer shell 4501 and the inner liner 4500 can help position the insulating layer 4502 such that the insulating layer covers a substantial portion of the inner liner 4500.

Specifically, as shown in FIG. 21 , the insulating layer 4502 occupies most of the space formed between the inner liner 4500 and the outer shell 4501 . Insulation layer 4502 extends substantially to the top of insulator 4010 in both the front and rear portions of insulator 4010 to insulate most of compartment 4504. Thus, the insulating layer 4502 surrounds substantially the entire interior chamber 4504 to provide the greatest amount of thermal insulation to the interior chamber 4504 of the insulating device 2010 . In one example, the insulating layer 4502 covers 80% or more of the liner 4500 (which covers the interior cavity 4504 ), and in certain examples, the insulating layer 4502 covers the liner 4500 (which covers the interior cavity 4504 ) 85%, 90% or 95% or more.

In the examples discussed with respect to FIGS. 11-22 , the forward facing closures 2311 , 4311 may be formed such that they extend along a substantial portion of the forward facing surface of the insulator 2010 , 4010 . As discussed above, according to the examples discussed herein, the forward facing closures 2311, 4311 may be formed as zipper closures. In one example, the closures 2311, 4311 can be substantially waterproof or highly waterproof, and can be both watertight and airtight. The forward facing closures 2311 , 4311 may be formed as long as possible in the forward facing surface of the thermal insulation device 2010 , 4010 to extend user accessibility and visibility of the contents stored in the thermal insulation device 2010 , 4010 . In one example, the closures 2311 , 4311 may define a first length L ₁ and the top of the insulation 4010 may define a second length L ₂ .

In one example, L ₂ may be 3 cm to 10 cm longer than the length L ₁ of the forward facing closures 2311 , 4311 , and in one particular example, may be 5 cm longer than the forward facing closures 2311 , 4311 . The _first length L1 of the closure 2311, 4311 may extend at least 80% of the _second length L2 and up to 98% of the _second length L2. In one particular example, the length L1 _of the closures 2311, 4311 may extend across 87% of the _second length L2.

Additionally, the length L ₁ of the forward facing closures 2311 , 4311 may be formed to be longer than the length L ₃ of the base of the thermal insulation device 2010 , 4010 . In some examples, the forward-facing closures 2311 , 4311 may be formed to be approximately 1% to 25% longer than the length L ₃ of the base of the insulator 4010 . In one particular example, the length L1 of the forward facing closures 2311, 4311 may be ₁₀ % longer than the length L3 _of the base. For example, the length L1 _of the forward facing closure may be formed to be ₃ cm to 12 cm longer than the length L3 of the base of the insulator, and in one particular example, the length L1 _of the forward facing closures 2311, 4311 may be longer than _The length L3 of the base is 5cm long.

In still other embodiments, the insulation may include closures extending around the entire perimeter or most of the perimeter of the insulation and forward facing closures 2311, 4311 as discussed above. In this particular example, once the entire top portion or most of the top portion is removed through the closure 2311, 4311, the contents of the thermal insulation device can be easily accessed by the user.

In another example, the insulation may be formed modular such that the top and/or bottom may be removed and multiple structures may be interconnected to form larger or smaller insulation. For example, the insulation may be formed from different sections by removable fasteners such as snaps, zippers, stitching, seals, hook and loop, etc.

With respect to the examples discussed herein, a series of vents may be provided along the housing of the thermal insulation device. The exhaust port allows any gas trapped between the liner and outer shell to escape. In the absence of a vent, gas trapped between the liner and outer shell may cause the thermal insulation to expand, which may be undesirable in some circumstances. In some instances, one or more joints or seams connecting portions of the housing provide vents for the gas. Air vents may be provided in the area of the casing where the casing fabric is pierced. For example, tiny openings can be provided at any stitching locations where various components are located on the thermal insulation. Specifically, vents may be provided in the area where handles, Molle loops, straps, reinforcement patches, adhesives, D-rings, loop patches, etc. are attached to the housing of the thermal insulation device. For example, the seams that can be used to secure these components to the housing provide openings into the housing, which create a vent between the insulation and the housing. In one particular example, the thermal insulation may be vented through the bond 4518.

Example insulation 4010 was tested to determine ice retention performance. In this way, the ice retention performance test can be used to determine the thermal insulation properties of the example thermal insulation device 4010. In an exemplary test, the duration of the increase from 0°F to 50°F when the insulator 4010 is filled with ice was determined according to the following test parameters. In certain instances, the temperature of the thermal barrier is increased from 10°F to 32°F over a duration of 24 hours to 48 hours, and the temperature of the thermal barrier is increased from 32°F to 50°F over a duration of 36 hours to 68 hours. °F, and the temperature of the insulation is increased from 0 °F to 50 °F over a duration of 70 to 90 hours.

Use the following test to test ice retention performance. More than 24 hours before the test, perform the following steps:

• Make sure the inside and outside of the test cooler are clean.

· Tag the test cooler with a unique identifier and record the identifier and description in the test log or note.

• Use adhesive tape to place the thermocouple (T) approximately in the center of the test cooler (C).

• The thermocouple tip should be approximately 1 inch above the cooler base plate. (See Figure 23 for an example of a suitable thermocouple setup.)

• Condition the test cooler by keeping it inside (ambient temperature 65°F-75°F) with the lid open for at least 24 hours.

· Use the formula below to calculate the amount of ice required for the test (to the nearest 0.1 lb).

ο Amount of ice in each cooler = 0.52 lbs x quart capacity of the cooler

ο Required ice volume = ice volume per cooler x number of coolers

· Condition the ice by placing it in the freezer (-15°F to -5°F) for at least 24 hours before use.

On the day of the test, perform the following steps:

· Obtain test equipment

Allow the thermal chamber temperature to reach 100°F

Balance - place the balance near the freezer with test ice

Data Logger - Make sure the data logger's battery is charged

The test steps are as follows:

• Bring the test cooler to the freezer with test ice.

• Place the test cooler on the balance and zero the balance.

• Break the test ice with a hammer.

• Using the balance as a reference, quickly fill the test cooler with the required amount of ice.

• Make sure the ice is evenly distributed throughout the test cooler.

• Make sure the connector end of the thermocouple is on the outside of the test cooler and close and secure the cooler cover.

• Repeat these steps for the remaining test coolers.

• Arrange the coolers in the test area so that they all have a uniform amount of direct sunlight and airflow (one cooler does not block the other).

• Connect all thermocouples to the data logger.

Check all thermocouple readings to ensure all connections are made and the channels are recorded correctly. (Note: The initial temperature inside each test cooler should be <10°F).

Power up the data logger and configure it to record temperature at intervals of less than 10 minutes.

· Start recording and note the time in the test log.

• Allow the test to continue until the internal temperature of each test cooler is ≥50°F.

• Stop recording.

• Disconnect the thermocouple from the data logger.

• Receive data from a data logger.

• Remove the test cooler from the test area.

• Empty the test cooler and allow it to dry.

• Remove the thermocouple from the test cooler.

The heat gain rate of the thermal insulation device 2010, 4010 may be about 0.5 to 1.5 degF/hr, and in one particular example, the heat gain rate may be about 1.0 degF/hr.

Similar to the above example, the performance of the thermal insulation devices 2010 and 4010 was also configured to withstand internal leakage and tests were also conducted to see the contents of the thermal insulation devices 2010, 4010 kept stored in the storage compartments or receptacles 2504, 4504 performance. In one example test, the thermal insulation 2010, 4010 may be filled with a liquid, such as water, and then inverted for a predetermined period of time to test for moisture leakage. In this example, insulation 2010, 4010 is filled with liquid until approximately half the volume of receptacle 4504 is filled (eg, 3 gallons of water), then closures 2301, 4301 are fully closed. The entire insulation 2010, 4010 is then inverted and held upside down for a period of 30 minutes. The thermal insulation 2010, 4010 is then checked for any leaks.

The thermal insulation 2010, 4010 can be configured to be able to be inverted for 30 minutes without any water escaping or leaving the receptacles 2504, 4504. In an alternative example, the thermal barrier 2010, 4010 may be configured to be able to be inverted for 15 minutes to 120 minutes without any water escaping or leaving the receptacles 2504, 4504.

Another example thermal insulation device 3010 is shown in FIGS. 24-32 . The example thermal insulation 3010 may have a similar construction to the examples above, wherein like reference numerals refer to like features with like functions. In this example, as can be seen in FIGS. 24-26 and 32 , closure 3311 and opening 3512 are formed through first side wall 3507A, second side wall 3507B and third side wall 3507C of insulator 3010 and Partially through the fourth side wall 3507D. Additionally, opening 3512 is configured to provide access to interior chamber 3504, as shown in FIGS. 29A and 32 . Similar to the example above, closure 3311 may be substantially waterproof so as to prevent liquid from flowing out of opening 3512 when thermal insulation 3010 is in any orientation.

As shown in the cross-sectional view of FIG. 29A , example insulation 3010 generally includes a body assembly 3350 and a cover assembly 3300 that together form the three main components of insulation 3010 : liner 3500 , insulation 3502 , and outer shell 3501 . The inner liner 3500 may be made of double-laminated TPU nylon fabric in one example, the insulation layer 3502 may be formed of an NBR/PVC foam blend or any other suitable blend or foam in one example, and the outer shell 3501 In one example may be formed from TPU nylon fabric. It is also contemplated that the inner liner and outer shell 3501 may be formed from one or more of PVC, TPU coated nylon, coated fabrics, and other weldable and/or waterproof fabrics.

As shown in FIGS. 24-26 , the closure 3311 extends between the body assembly 3350 and the cover assembly 3300 to substantially waterproof the body assembly 3350 and the cover assembly 3300 . Additionally, as shown in FIG. 29A, the cover assembly 3300 may be connected to the body assembly 3350 by a housing 3501 that forms a living hinge 3503. In one example, living hinge 3503 may be formed as part of outer shell 3501 and/or liner 3500, and in particular by the flexible nature of the materials of outer shell 3501 and/or inner liner 3500, to provide greater flexibility in thermal insulation 3010. big opening. Living hinge 3503 may also be reinforced by inner fabric piece 3503A, which may be formed from a lining material or other waterproof material. In this way, the chamber 3504 and contents of the thermal insulation device 3010 can be accessed by opening the closure 3311 and folding back or opening the lid assembly 3300.

In this example, the thermal barrier 3010 may be in the shape of a cuboid or a prism. For example, the outer shell 3501, the insulating layer 3502, and the inner liner 3500 define a first side wall 3507A, a second side wall 3507B, a third side wall 3507C, and a fourth side wall 3507D of a cuboid. The cover assembly 3300 also forms a top wall 3300a, while the base 3215 forms a bottom wall 3215a to close the cuboid. However, the contents of the insulator 3010 are accessed through an opening 3512 formed in the top of the insulator, and this opening may again extend through the Each and may extend partially through the fourth sidewall 3507D. Other shapes are also contemplated for insulator 3010, eg, cylindrical, spherical, conical, pyramidal, frustoconical, frustospherical, frustoconical, and the like. The height of insulator 3010 may range from 15 cm to 50 cm in one example, and may be 29 cm in one specific example. The length of the insulator 3010 may range from 15 cm to 50 cm, and in one particular example may be 32 cm. Likewise, the width of the insulation may range from 15 cm to 50 cm in one example, and may be 25.5 cm in one specific example. The storage capacity of thermal insulation device 3010 may be 10 to 15 quarts, and in one particular example may be 12.7 quarts. However, it is contemplated that the thermal barrier 3010 may comprise any height, length, width and volume dimension without departing from the scope of the present disclosure.

Similar to the examples above, the thermal barrier 3010 may include one or more handles 3210 and 3212, a loop 3214, and for attaching various items such as straps (shoulder straps), safety buckles, dry bags, keys, storage boxes, etc. ) of the webbing loop 3224. The loop 3214 can be a D-ring, and shoulder straps (not shown) can be attached to the D-ring to facilitate carrying the thermal insulation. Likewise, the rings 3214 can be attached to the insulator 3010 at attachment points 3213 which can form loops or straps 3315a that also form slots for receiving the rings 3214. The thermal insulation may also include side, front and/or rear handles, pockets, tethers and D-rings anywhere on the outer surface of the housing. The pockets can be sized to receive keys, phones, wallets, etc., and can be formed to be waterproof. The pockets can also include waterproof zippers to keep their contents from getting wet.

Also, similar to the examples above, the housing 3501 may also include a plurality of reinforced areas or patches 3320 configured to help structurally support optional handles, straps and webbing loops (eg 3210, 3212, 3213, 3214 and 3224). Handles or straps (eg, 3210, 3212, 3213, 3214, and 3224) and other attachments can be sewn to the patch using sutures 3222. In some instances, the stitches 3222 do not extend through the outer shell 3501 into the insulating layer 3502. Optional handles or straps can be sewn to patch 3320, and patch 3320 can be RF welded to housing 3501. Additionally, in other examples, the patch 3320 may be sewn or adhered to the housing 3501. The holes created by the stitching operation may provide venting to the interior defined by the outer shell 3501 and the inner liner 3500 of the thermal insulation device 3010. Additionally, other techniques for securing handles or straps to thermal insulation 3010 are contemplated.

The internal components of insulator 3010, body assembly 3350, and cap assembly 3300 can be seen in the cross-sectional view of Figure 29A. Additionally, FIG. 29B shows an enlarged cross-sectional view of the cap assembly 3300.

The cover assembly 3300 includes an upper liner portion 3500A, an upper insulating layer portion 3502A, and an upper outer shell portion 3501A. The upper insulation layer portion 3502A may be formed from a single foam layer, which corresponds to the overall shape of the cover assembly 3300. In one example, the foam may be insulating foam as discussed herein, which may be the same foam used in body assembly 3350, and may not be attached to upper liner portion 3500A and upper shell portion 3501A Instead it floats between them. As shown in FIG. 29B, the upper liner portion 3500A may be formed from a sheet of material 3500A1 and a strip of material 3500A2 attached to a bond 3518. In other embodiments, the sheet of material 3500A1 may be attached directly to the bond 3518, thereby eliminating the need for strips of material 3500A2. Strips of material 3500A2 may overlap and be welded to sheet of material 3500A1. A seam tape 3509 may be placed on the connection between the sheet of material 3500A1 and the strip of material 3500A2. For example, it is also contemplated that the upper liner portion 3500A may be formed as a unitary structure by injection molding.

The upper liner portion 3500A may be connected to the upper shell portion 3501A by joining the upper liner material strip 3500A2 to the upper shell material strip 3501A3 at the RF weld joint 3522. However, it is contemplated that other types of securing methods may be used, such as other forms of welding, stitching, adhesives, rivets, and the like. Additionally, as will be discussed in further detail, a strip or strip of adhesive material 3518 may be sewn over the ends of the upper strips of liner material 3500A2 and upper shell material 3501A3. It is also contemplated that the bonding material 3518 may be coupled over the ends of the upper strips of liner material 3500A2 and upper shell material 3501A3 by a plurality of rivets or by the use of one or more adhesives.

As shown in Figures 29A and 29B, the upper shell portion 3501A of the cover assembly 3300 may include two separate layers 3501A1 and 3501A2 and an upper strip of housing material 3501A3 extending perpendicular to the two separate layers 3501A1 and 3501A2. The upper shell material strip 3501A3 may be integral and attached to the first shell section 3501B1, as discussed in further detail below. For example, the upper strip of shell material 3501A3 and the first shell section 3501B1 may be formed from or cut from the same material. However, it is also conceivable that the strip of shell material 3501A3 and the first shell section 3501B1 are formed from separate structures or different materials. In one example, the top layer 3501A1 can be formed from a TPU coated nylon laminate, while the bottom layer 3501A2 can be formed from a compression molded EVA material. For example, the upper housing portion 3501A may also be formed from a single piece of material in an injection molding process.

As shown in FIGS. 29A and 29B , the adhesive material 3518 can both secure the lid assembly 3300 together and secure the lid assembly 3300 to the body assembly 3350. In some examples, the adhesive material 3518 may be formed from a strip, tape, or ribbon, and may be made of nylon. It is contemplated that the bonding material 3518 may be formed from additional or alternative polymers without departing from the scope of the present disclosure. Specifically, the first shell section 3501B1 may be secured to the upper liner 3500A, the separate layers 3501A1 and 3501A2, and the upper shell material strip 3501A3 of the upper shell portion 3501A by sewing the adhesive material 3518 around the perimeter of the cap assembly 3300 together. Thus, the stitching extends through adhesive material 3518, lower shell portion 3501B, upper liner portion 3500A, top layer 3501A1, bottom layer 3501A2 and strip of material 3500A2 to form seam 3517.

The weld joint 3522 can both secure the cap assembly 3300 together and secure the cap assembly 3300 to the body assembly 3350. As described above, the weld joint 3522 (which may be an RF weld joint) also connects the upper liner portion 3500A and the upper shell portion 3501A by joining the upper liner material strip 3500A2 to the upper shell material strip 3501A3 to connect the cap assembly 3300 fixed together. However, it is also contemplated that the joint 3522 may be formed by stitching or by adhesive. Likewise, once the lid assembly 3300 and the body assembly 3350 are secured together, a living hinge 3503 is formed between the lid assembly 3300 and the body assembly 3350.

The lid assembly 3300 and the body assembly 3350 are also connected by a closure, which in one example may be a zipper, as discussed below. Specifically, the zipper tape 3306 may be attached between the upper strip of shell material 3501A3 and the first shell section 3501B1 of the lower shell portion 3501B by stitching, welding, adhesive, or the like. In this way, the upper portion 3306a and the lower portion 3306b of the zipper tape 3306 secure the lid assembly 3300 and the body assembly 3350 together.

Referring again to Figure 29A, the body assembly 3350 includes a lower liner portion 3500B, a lower insulation portion 3502B, and a lower outer shell portion 3501B. Lower liner portion 3500B may be formed from top strip 3500B1, middle portion 3500B2, and bottom portion 3500B3. Top strip 3500B1 , middle portion 3500B2 and bottom portion 3500B3 may be welded or sewn together at seam 3508 . Seam 3508 may be covered with seam tape 3509, which may be formed of a waterproof or water resistant material such as PU (polyurethane). However, seam strip 3509 may be formed of a breathable material that is impermeable to water but allows gas to escape from interior cavity 3504.

In an alternative example, the lower liner portion 3500B may be formed from a single unitary piece, eg, by injection molding. Figure 31 shows an example liner portion 7500B formed by an injection molding process. In this example, the lower liner portion 7500B may be formed from one or more of polyurethane, PVC, TPU, or other weldable materials. After the lower insulation is placed within the outer shell, the lower liner portion 7500B can be welded into place on the outer shell.

Referring again to FIGS. 29A and 30 , the lower insulating layer portion 3502B may include a first sheet 3502B1 of insulating material and a second sheet 3502B2 of insulating material. Similar to the example above, the first sheet of insulating material 3502B1 and the second sheet of insulating material 3502B2 may be free-floating layers of insulating material that are not attached to the lower liner portion 3500B or the lower shell portion 3501B. However, it is also contemplated that the first sheet of insulating material 3502B1 and the second sheet of insulating material 3502B2 may be attached to the lower liner portion 3500B or the lower shell portion 3501B. Additionally, it is also contemplated that the lower thermal barrier portion 3502B is formed from a single unitary piece.

The lower housing portion 3501B may be formed from several segments. In this example, the lower shell portion 3501B can include a first shell section 3501B1, a lower outer wall section 3501B2, a first base layer 3501B3, and a second base layer 3501B4. Similar to the cover assembly, the first base layer 3501B3 can be formed from a TPU coated nylon laminate, while the second base layer 3501B4 can be formed from a compression molded EVA material. Each of the lower outer wall section 3501B2, the first base layer 3501B3 and the second base layer 3501B4 may be joined together by sewing, welding or adhesive. Also, similar to the examples above, base support ridges 3400 may be formed into the first base layer 3501B3 and the second base layer 3501B4 to provide structural integrity and support for the insulation 3010 when placed on a surface. In alternate examples, the lower housing portion 3501B may be formed as a single piece, and in some examples, may be formed by an injection molding process.

Similar to the example above, the closure 3311 can be a zipper and can be substantially waterproof. Additionally, the zipper may include a pull tab or handle 3302, which in this example may be formed of hard plastic. It is also contemplated that the pull tab 3302 may be formed of metal or alloy, flexible polymer, cloth, wire or cord, and the like. Forming the pull tab 3302 from fabric, thread or cord can prevent fraying of the connection between the pull tab 3302 and the zipper. Specifically, when the zipper is closed around the circumference of the housing 3501, the pull tab 3302 can be rotated or twisted by the user. The fabric, thread or rope can withstand the twisting action of the user. Other pull tabs are also conceivable. For example, the pull tab may be provided with a bearing connection that allows the pull tab to rotate 360° in all directions.

A series of vents may be provided along the housing 3501 of the thermal insulation device 3010. The vent allows any gas trapped between the liner 3500 and the outer shell 3501 to escape. Without a vent, gas trapped between the liner 3500 and the outer shell 3501 would cause the insulation 3010 to expand, which may be undesirable in some circumstances. In some instances, the joint or seam connecting the liner and the outer shell provides a vent to the gas.

Venting may be provided in cap assembly 3300 . Specifically, in cap assembly 3300, seam 3517 may provide a series of small openings in cap assembly 3300 where stitching lines on adhesive material 3518 occur. These openings serve as vents for gas to escape the interior volume of cap assembly 3300 .

Additionally, venting may be provided in the body assembly 3350. In the body assembly, a vent may be provided in the area of the lower housing portion 3501B where the fabric of the lower housing portion 3501B is pierced. For example, as shown in FIG. 26 , a slight opening may be provided at the frame and cruciform stitching 3521 where the rear handle 3210 is attached to the insulator 3010. Air vents may also be provided at areas or locations where handle 3212, handle 3210, Molle ring 3224, and D-ring 3214 are attached to housing 3501 of insulator 3010. For example, the sutures securing the handle, webbing or Molle loop 3224 and D-ring 3214 to the housing provide an opening into the housing 3501 to form a storage compartment or venting of the interior chamber 3504 of the insulator 3010. FIG. 33 shows an example schematic in which suture 3519 extends through housing 3501 , handle 3212 , reinforcement area or patch 3320 .

To form insulator 3010 , body assembly 3350 may be formed, and cover assembly 3300 may then be formed by joining cover assembly 3300 to body assembly 3350 . To form the body assembly 3350 of the insulator 3010, the lower shell portion 3501B and the lower liner portion 3500B may be formed independently. Once the lower housing portion 3501B is formed, the insulating layer 3502 can be placed within the lower housing portion 3501B. The lower liner portion 3500B may be attached to the lower shell portion 3501B to secure the insulating layer 3502 within the lower shell portion 3501B and the lower liner portion 3500B. However, the insulating layer 3502 is free to float between the lower shell portion 3501B and the lower liner portion 3500B. Cap assembly 3300 may be secured together and cap assembly 3300 may be secured to body assembly 3350 by welding upper liner portion 3500A to upper shell portion 3501A and lower shell portion 3501B at weld joint 3522. Finally, the cover assembly 3300 can be further attached to the lower housing portion by sewing together the top portion of the lower housing portion 3501B with the top layer 3501A1, bottom layer 3501A2, upper liner portion 3500A, strip of material 3501A3, and adhesive material 3518 3501B.

Specifically, the lower housing portion 3501B may be formed by attaching each of the first housing section 3501B1, the lower housing section 3501B2, the first base layer 3501B3, and the second base layer 3501B4 together. Next, each of the first sheet of insulating material 3502B1 and the second sheet of insulating material 3502B2 may be placed within the lower housing portion 3501B. The lower liner portion 3500B may then be formed by welding each of the top strip 3500B1, the middle portion 3500B2, and the bottom portion 3500B3 together, followed by adding seam tape 3509 to each weld. Alternatively, as discussed above, the lower liner portion 3500B may be formed by injection molding the material. Once the lower liner portion 3500B is formed, the liner portion 3500B can be placed within the lower insulation portion 3502B, and the liner portion 3500B can be positioned at seam 3511 all the way along the inner perimeter of the body assembly 3350 of the insulator 3010 is welded to the lower housing portion 3501B. In this example, seam 3511 may be formed by welding or sewing.

FIG. 9 shows an exemplary welding technique that may be used to weld the lower liner portion 3500B to the lower shell portion 3501B. Once the lower liner portion 3500B is placed within the lower insulation portion 3502B, a three-piece tool can be used to join the lower liner portion 3500B to the lower shell portion 3501B on its sides, which can include a top U-shaped portion 3514A, plate portion 3516, and bottom U-shaped portion 3514B. The curvature of the top U-shaped portion 3514A, the plate portion 3516 and the bottom U-shaped portion 3514B may correspond to the shape of the perimeter of the body assembly 3350 of the thermal insulator 3010.

To form seam 3511 as a weld, lower liner portion 3500B is brought into contact with lower shell portion 3501B, and plate portion 3516 is placed within lower liner portion 3500B and top U-shaped portion 3514A, and bottom U-shaped portion 3514B may be placed In contact with the lower housing portion 3501B. The top U-shaped portion 3514A and the bottom U-shaped portion 3514B can be connected to two leads so that current can pass through the top U-shaped portion 3514A, the lower housing portion 3501B and the lower liner portion 3500B. Electric current may then be first applied to the top U-shaped portion 3514A to form a weld along the top U-shaped portion 3514A including the curved portion and the straight portion. After the top section is soldered, the polarity of the leads can be reversed and then the bottom section is soldered along the bottom U-shaped portion 3514B.

After welding the bottom section through the bottom U-shaped portion, the remaining two sides can then be welded by using the plate portion 3516 and a pair of straight side bars or another clamping mechanism or vice. Similar to the curved portion of the body assembly 3350, electrical current can be applied to a pair of straight side rods through wires. Likewise, the sides can be welded separately by applying current in a first direction to weld the first side, and then by switching the polarity of the leads and running the current in the opposite direction to weld the second side. In one example, each of these segments can be welded for about 10 seconds. Once the welding is completed around the entire perimeter of the body assembly 3350, the body assembly 3350 can be assembled to the cap assembly 3300.

In one example, the closure 3311 may be substantially waterproof, such that when the insulation is dropped from a height of six feet, liquid is prevented from flowing out of the opening. In this test, the insulation can be completely filled with water and then dropped from a height of six feet to contact the concrete surface with each of the multiple faces (six in this case) of the insulation 3010.

Example insulation 3010 was tested to determine ice retention performance. In this way, the ice retention performance test can be utilized to determine the thermal insulation properties of the example thermal insulation device 3010. In an exemplary test, the duration of the increase from 0°F to 50°F when the insulator 3010 is filled with ice was determined according to the following test parameters. In certain instances, the temperature of the thermal insulation is increased from 0°F to 10°F over a duration of 0.5 hours to 1.5 hours, and the temperature of the thermal barrier is increased from 10°F to 50°F over a duration of 22 hours to 28 hours. °F, and the temperature of the insulation is increased from 0 °F to 50 °F over a duration of 24 hours to 30 hours.

Use the following test to test ice retention performance. More than 24 hours before the test, perform the following steps:

Make sure the inside and outside of the test cooler are clean.

Tag the test cooler with a unique identifier and record the identifier and description in the test log or note.

Use adhesive tape to place the thermocouple (T) approximately in the center of the test cooler (C).

The thermocouple tip should be about 1" above the cooler base plate. (See Figure 11 for an example of a suitable thermocouple setup.)

Condition the test cooler by keeping it inside (ambient temperature 65°F-75°F) with the lid open for at least 24 hours.

Use the formula below to calculate the amount of ice required for the test (to the nearest 0.1 lb).

Amount of ice in each cooler = 0.52 lbs x quart capacity of the cooler

Required ice volume = ice volume per cooler x number of coolers

Condition the ice by placing it in the freezer (-15°F to -5°F) for at least 24 hours before use.

On the day of the test, perform the following steps:

Get test equipment

Let the thermal chamber temperature reach 100°F

Balance - place the balance near the freezer with test ice

Data Logger - Make sure the data logger's battery is charged

The test steps are as follows:

Bring the test cooler to the freezer with test ice.

Place the test cooler on the balance and zero the balance.

Break the test ice with a hammer.

Using the balance as a reference, quickly fill the test cooler with the required amount of ice.

Make sure the ice is evenly distributed throughout the test cooler.

Make sure the connector end of the thermocouple is on the outside of the test cooler and close and secure the cooler cover.

Repeat these steps for the remaining test coolers.

Arrange the coolers in the test area so that they all have an even amount of direct sunlight and airflow (one cooler does not block the other).

Connect all thermocouples to the data logger.

Check all thermocouple readings to make sure all connections are made and the channel is logged correctly. (Note: The initial temperature inside each test cooler should be <10°F).

Power up the data logger and configure it to record temperature at intervals of less than 10 minutes.

Start recording and note the time in the test log.

Allow the test to continue until the internal temperature of each test cooler is ≥50°F.

Stop recording.

Disconnect the thermocouple from the data logger.

Receive data from the data logger.

Remove the test cooler from the test area.

Empty the test cooler and allow it to dry.

Remove the thermocouple from the test cooler.

Two samples were tested according to the procedure described above. The test results are reflected below.

35A-36B illustrate various views of another exemplary thermal insulation device 5010. The example thermal insulation 5010 is similar to the examples discussed above with respect to FIGS. 24-30 . Like reference numerals refer to the same or similar elements of similar function throughout the various views. Therefore, these elements will not be described in detail. However, in this example, the exemplary insulation 5010 can be formed in a smaller size, can include a top handle 5216, and can include optional reinforcement pieces or pieces. However, it is contemplated that the examples of thermal insulation discussed herein may include similar top handles and reinforcement pieces or pieces.

36A and 36B show partial views of an example cap assembly 5300. 35A shows a partial cross-sectional view of an example cap assembly 5300. The example cover assembly 5300 is similar to the example above, however reinforcement pieces or pieces 5217 may be additionally included in the cover assembly 5300. FIG. 36B shows a partial top view of an example cap assembly to illustrate the reinforcement tabs 5217. Reinforcing tabs or pieces 5217 are configured to help prevent handle 5216 and cap assembly 5300 from flexing. Compared to the outer liner 5501, the insulating layer 5502, and the inner layer 5500, the reinforcing sheet or piece 5217 may be a relatively rigid sheet of material. In one particular example, the reinforcing sheets or tiles 5217 may be formed from a suitable polymer or plastic such as polyethylene. However, any flexible reinforcement material may be used, and other examples may include thermoformed PE, TPU injection molded custom parts.

In some instances, the reinforcing sheets or tiles 5217 may be flat, corrugated, or may have a honeycomb-like configuration. However, the pieces 5217 may include other patterns to help prevent the handle 5216 from flexing. In some instances, the reinforcement pieces or tiles may be 1 mm to 3 mm thick. The reinforcement sheet can include a cover, which, in some instances, can be configured to prevent penetration of water into the cover. In other examples, additional fabric may be included to enhance the handle.

A reinforced area or patch 5320 may be included on the cover assembly 5300 for supporting the handle 5216. In some instances, the patch 5320 can be welded to the cap assembly 5300. However, the patch 5320 may also be omitted entirely. The handle 5216 may be sewn to the cover assembly 5300 and the reinforcement panel 5217 by stitching 5219. The handle 5216 may also extend through the cover assembly and be oriented to connect to the reinforcement piece 5217. Additionally, instead of using sutures, the handle 5216 may be attached to the reinforcement piece or piece 5217 by one or more welds, bolts or other threaded connections, bayonet, ball and socket, or the like. Other methods of attachment may include providing layers 5501A1 or 5501A2 with one or more slots, and providing reinforcing sheets or tiles 5217 with one or more corresponding protrusions that may be located within the one or more slots, which allow the sheet or More advanced connection of tile 5217 to cover assembly 5300 of thermal insulation 5010. Likewise, a wire frame or wire can be placed within handle 5216 and extend through handle 5216. A wire frame or wire may be threaded through the sheet or piece 5217 to secure the handle to the closure assembly 5300. It is also contemplated that all or part of the closure assembly and/or handle may be injection molded to provide a more rigid structure to prevent the handle from flexing.

The connection between the handle 5216 and the reinforcement piece 5217 also helps prevent separation issues between the separate layers 5501A1 and 5501A2, which can be TPU coated nylon laminate and compression molded EVA, respectively Material. In this example, the connection between the handle and the reinforcement piece may allow water to enter the cover. At the same time, however, the connection may allow any liquid therein to escape through evaporation through the opening formed by the connection. However, it is also conceivable that the connection between the handle and the reinforcement piece may also be waterproof or water resistant to limit the amount of moisture entering the closure assembly.

The handle 5216 may also be formed of 1000D nylon or other suitable polymer, and may include 50mm webbing. Additionally, the handle 5216 may include padding on the grip portion of the handle. In one example, the pad may be a suitable foam, such as 5mm polyethylene sponge foam. It is contemplated that the seal between the cover assembly 5300 and the body assembly 5350 may be configured to withstand the impact load of the handle when the thermal barrier 5010 is sealed and filled with content. However, side bridges connecting the cover assembly 5300 to the body assembly 5350 are also contemplated for transporting heavy objects in the thermal insulation device 5010.

37 depicts an isometric view of a front portion of an insulator 6010 in accordance with one or more aspects described herein. Additionally, FIG. 38 depicts an isometric view of the back portion of the same insulator 6010. As depicted in Figure 38, the insulation 6010 includes a back support panel 6602 and shoulder straps 6604A and 6604B that allow the insulation 6010 to be carried as a backpack. The thermal insulation 6010 may have a similar construction to the examples described earlier in this disclosure, wherein like reference numerals refer to like features with like functionality. In one example, features identified by the same last three digits and optionally the same letter or alphanumeric suffix may be considered to include similar features and materials and/or methods of construction. It is contemplated that the structures of thermal insulation 6010 may be coupled to each other by any method and/or fastener elements, such as those previously described throughout this disclosure, and include, among other things, adhesives, sutures, laser welding and/or or rivets.

FIG. 39 depicts a front elevation view of a thermal insulation device 6010 in accordance with one or more aspects described herein. It is contemplated that thermal insulation 6010 may include any dimension of height, width, and depth without departing from the scope of the present disclosure. Furthermore, it is contemplated that the various components or sub-components of thermal insulation device 6010 may have any dimensions without departing from the scope of the present disclosure. FIG. 39 schematically depicts the width 6802 and height 6804 of the insulator 6010 . FIG. 40 schematically depicts the depth 6806 of the thermal insulation 6010 . In one particular example, width 6802 may measure approximately 28 cm. In another example, the width 6802 may range between approximately 24 and 32 cm. Additionally, height 6804 may measure approximately 48 cm. In another example, the height 6804 may range between approximately 44 and 52 cm. Additionally, the depth 6806 may be measured to be approximately 22 cm. In another example, the depth 6806 may range between approximately 16 and 28 cm. However, it is contemplated that the insulator 6010 may have any size. In one example, insulator 6010 may have a substantially cubic geometry. Additionally or alternatively, the geometry of the insulator 6010 may have one or more rounded or rounded edges. However, it is contemplated that the thermal insulator 6010 may have any different geometry, such as a substantially cylindrical geometry, without departing from the scope of the present disclosure.

As depicted in FIG. 39, thermal insulation 6010 includes a plurality of fabric loops 6224 similar to loops 224 previously described. Specifically, as depicted in Figure 39, there are six loops 6224 in each of the two rows, each of which is coupled to the first side wall 6507A. It is contemplated, however, that any number of loops 6224 may be used, and may form a single row or three or more rows, without departing from the scope of the present disclosure.

40A depicts a side elevational view of a first or right side of an insulator 6010 in accordance with one or more aspects described herein. In one example, thermal insulation 6010 includes attachment panels 6606 . Attachment panel 6606 may include surfaces configured to removably couple hook and loop fasteners to exterior elements (exterior elements are not shown, but may include one or more storage racks, straps, pockets, etc. or pouches, etc., especially including hook and loop attachment elements). It is contemplated that the attachment panel 6606 may include one or both of hook and loop attachment elements of a hook and loop fastener structure. Additionally or alternatively, the attachment panel 6606 may include and/or encapsulate one or more metallic and/or magnetic elements configured to be removably coupled to one or more external magnetic elements (not shown).

FIG. 40B depicts an alternate embodiment of the right side of the thermal insulation device 6010. As such, insulator 6010 may include a series of attachment loops 6224 in place of attachment panels 6606. Additionally, the insulation 6010 may include a waist strap 6810, which will be described in further detail with respect to FIG. 44 . It is contemplated that the waist strap 6810 may be used in conjunction with any embodiment of thermal insulation described throughout this disclosure, including the embodiment shown in Figure 40A.

41 depicts a side elevational view of a second or left side of an insulator 6010 in accordance with one or more aspects described herein. As depicted in Figure 41, the thermal insulation 6010 includes a plurality of fabric loops 6224 similar to the loops 224 previously described. Although four loops 6224 are depicted in Figure 41, it is contemplated that any number of loops 6224 may be used without departing from the scope of the present disclosure. Additionally, it is contemplated that the second side of the insulator 6010 depicted in FIG. 41 may include an attachment panel similar to the attachment panel 6606. Additionally or alternatively, it is contemplated that the first side of the thermal insulation device 6010 depicted in FIG. 40 may include an attachment loop similar to the loop 6224 depicted in FIG. 41 .

FIG. 42 depicts a front view of the rear side of an insulator 6010 in accordance with one or more aspects described herein. In one example, the back support panel 6602 is coupled to the depicted reinforced patch 6320 and the fourth side wall 6507D of the insulation 6010. The shoulder straps 6604A and 6604B can include padded upper strap portions 6702A and 6702B, which can be constructed using similar materials and processes as the straps 218 . In one example, the padded upper strap portions 6702A and 6702B may comprise multiple layers of material, including a foam core surrounded by an abrasion resistant polymer shell. As such, the foam core may include ethylene vinyl acetate polymers, low density polyethylene, nitrile rubber, neoprene foam, polyimide foam, polypropylene foam, polyurethane foam, polyvinyl chloride foam, silicone foam, and One or more of the microcellular foams or a combination thereof. Additionally, the padded upper strap portions 6702A and 6702B may include outer webbing sewn onto the padded upper strap portions 6702A and 6702B to form a plurality of loops 6716. A portion of the loop 6716 is marked on each of the padded upper strap portions 6702A and 6702B in FIG. 42 .

It is contemplated that the padded upper strap portions 6702A and 6702B may include any number of loops 6716, which may be of any physical size. These loops may be similar to loops 224 and may be constructed of nylon webbing. Additionally or alternatively, the loop 6716 may be constructed of other materials such as polypropylene, neoprene, polyester, Dyneema fibers, Kevlar fibers, cotton, leather, plastic, rubber, or rope. It is contemplated that loop 6716 is configured for attaching items (eg, safety buckles, dry bags, etc.) to insulation 6010. Additionally or alternatively, the loop 6716 is configured to limit the extent to which the padded upper strap portions 6702A and 6702B may extend. As such, the padded upper strap portions 6702A and 6702B may be constructed of a material that is configured to deform and expand to provide cushioning when the thermal insulation device 6010 is worn on the back of the user. The padded upper strap portions 6702A and 6702B can be in a retracted position and the loop 6716 can have a retracted position from the padded upper strap when the user is not loading or carrying the thermal insulation device 6010. The portions 6702A and 6702B loop outwardly with a certain amount of slack. When worn by the user, the weight of the insulation 6010 may intermittently or continuously cause the padded upper strap portions 6702A and 6702B to extend, and the loops 6716 The outer surfaces of the upper strap portions 6702A and 6702B. In this way, the loop 6716 can be configured to limit the extent to which the padded upper strap portions 6702A and 6702B can stretch, thereby preventing overstretching and damage to the padded upper strap portions 6702A and 6702B, while also providing shock absorption.

In one example, padded upper strap portions 6702A and 6702B can be coupled to the top portion of back support panel 6602 at proximal ends 6704A and 6704B. It is contemplated that the padded upper strap portions 6702A and 6702B may be coupled to the back support panel 6602 at the proximal ends 6704A and 6704B by sewing, gluing, or one or more fastener elements, or the like. The shoulder straps 6604A and 6604B may additionally include lower adjustment straps 6706A and 6706B. Lower adjustment straps 6706A and 6706B can be coupled to the bottom portion of back support panel 6602 at proximal ends 6708A and 6708B. Lower adjustment straps 6706A and 6706B may be constructed of a material similar to loop 6716 and webbing 212 . As such, in one example, the lower adjustment straps 6706A and 6706B may be formed from nylon webbing.

The distal ends 6710A and 6710B of the padded upper strap portions 6702A and 6702B can be adjustably coupled to the distal ends 6712A and 6712B of the lower adjustment straps 6706A and 6706B by adjustment buckles 6714A and 6714B. In one example, the adjustment buckles 6714A and 6714B may be constructed of one or more of polymers, metals, alloys, ceramics, or fiber reinforced materials, among others. Additionally, the distal ends 6712A and 6712B of the lower adjustment straps 6706A and 6706B may include stitched loops that provide finger loops to allow the lower adjustment straps 6706A and 6706B to be grasped and pulled through the adjustment buckles 6714A and 6714B and added to the lower The thickness of the adjustment straps 6706A and 6706B makes it less likely that the adjustment straps 6706A and 6706B will accidentally slip through and out of the adjustment buckles 6714A and 6714B.

Thermal insulation 6010 may additionally include lower attachment rings 6718A and 6718B. The lower attachment loops 6718A and 6718B can be sewn into the sides of the back support panel 6602 and can be constructed of a material similar to the lower adjustment straps 6706A and 6706B. It is contemplated that the lower attachment loops 6718A and 6718B may be constructed of nylon webbing material. However, additional or alternative materials may be used without departing from the scope of the present disclosure. In one example, lower attachment loops 6718A and 6718B may serve as anchor points for attaching waist straps (not shown) to insulation 6010.

In one embodiment, the thermal barrier 6010 may include a loop handle 6720, also referred to as a drag handle 6720. A loop handle 6720 can be sewn into the insulation 6010 at the top portion of the back support panel 6602 and can be constructed of nylon webbing, similar to the lower attachment loops 6718A and 6718B. It is contemplated, however, that the loop handle 6720 may be constructed of additional or alternative polymer, metal, alloy, or ceramic materials without departing from the scope of the present disclosure. In one example, the loop handle 6720 may additionally include padding material encapsulated within nylon webbing. The padding material may comprise foam, or one or more layers of nylon webbing. In another embodiment, a loop handle 6720 can be sewn into the back portion or fourth side wall 6507D of the insulator 6010 above the back support panel 6602.

43 schematically depicts a cross-sectional view of a thermal insulation device 6010 in accordance with one or more aspects described herein. In one example, thermal insulation 6010 may include similar elements to thermal insulation 5010, as schematically depicted in Figure 35F. Additionally, the thermal insulation 6010 includes a back support panel 6602. In one example, the back support panel 6602 includes an outer layer 6608 and an inner layer 6610 through one or more fasteners, including sewing, and/or through adhesive bonding similar to the adhesive 518 The knots 6518 bind to each other as previously described. In one example, the back support panel 6602 can be coupled to the housing section 6501 . Additionally, the shell section 6501 may have two or more layers 6501B1 at the back portion or fourth side wall 6507D where the back support panel 6602 is coupled to the thermal insulation 6010. In one embodiment, the inner layer 6610 of the back support panel 6602 may comprise compression molded ethylene vinyl acetate (EVA). In another example, the inner layer 6610 may additionally or alternatively comprise another polymeric foam material such as, inter alia, low density polyethylene, nitrile rubber, neoprene foam, polyimide foam, polypropylene foam, Polyurethane foam, polyvinyl chloride foam, silicone foam, and microcellular foam, or a combination thereof. In one embodiment, the outer layer 6608 may comprise a nylon material and polymerized leather. However, it is contemplated that the outer layer 6608 may include additional or alternative materials. In one embodiment, the material and thickness of the back support panel 6602 can be configured to provide stiffness to deformation/increase when the insulation 6010 is worn as a backpack and the back support panel 6602 is positioned proximate the user's back Provides increased stiffness to hold the insulation 6010 in an upright position (not shown) when not worn as a backpack. It is contemplated that any material thickness and material type may be used in the construction of the back support panel 6602 in addition to or in lieu of the foregoing, including polymers, metals, alloys, fiber reinforcements, or combinations thereof.

Thermal insulation 6010 includes an interior chamber 6504 similar to interior chambers 504, 2504, 3504, and 4504, and is configured to store one or more items and reduce the rate of heat transfer to and from there. It is contemplated that the volume of the interior chamber 6504 may have any value without departing from the scope of the present disclosure.

It is contemplated that the insulating layers 6502A, 6502B, 6502B2 may comprise any of the insulating materials previously described throughout this disclosure. Additionally or alternatively, the insulating layer depicted in Figure 43 may include one or more vacuum insulated panels. These vacuum insulated panels are further described in PCT/US2016/063658, filed November 23, 2016, the contents of which are incorporated herein by reference.

In another example, thermal insulation 6010 may include additional reinforcement structures. In one example, these additional reinforcement structures may include one or more of an inner frame, an outer frame, or a portion of an inner frame formed by one or more panels, tubes, and/or The beams are also constructed of one or more of metals, alloys, ceramics, or fiber reinforced materials, or a combination thereof. In another embodiment, the interior chamber 6504 of the thermal insulation device 6010 may include one or more storage compartments, pockets, dividers, or other structures without departing from the scope of the present disclosure.

FIG. 44 depicts another isometric view of thermal insulation device 6010. As shown, waist strap 6810 is removably attached to lower attachment loops 6718A and 6718B. In one example, the waist strap 6810 includes a first strap portion 6812 that is removably coupled to a second strap portion 6814 by a buckle 6816. It is contemplated that the first strap portion 6812 and the second strap portion 6814 may be constructed of nylon webbing, similar to the lower adjustment straps 6706A and 6706B. However, additional or alternative polymer, metal, alloy or ceramic materials or combinations thereof may be used in the first strap portion 6812 and the second strap portion 6814 without departing from the scope of the present disclosure. It is further contemplated that the buckle 6816 may include any releasable coupling embodiment without departing from the scope of the present disclosure.

The waist strap 6810 can be removably attached to the lower attachment loops 6718A and 6718B by two gap ring fasteners 6818A and 6818B. In one example, the gap ring fasteners 6818A and 6818B can be constructed of aluminum and can include elongated loop elements having a gap configured to allow the lower attachment loops 6718A and 6718B to pass therethrough. In other embodiments, the gap ring fasteners 6818A and 6818B may be constructed of another metal, alloy, polymer, fiber-reinforced material, or ceramic, or a combination thereof.

Figure 44 further depicts an alternate embodiment of the shoulder straps 6820A and 6820B. The shoulder straps 6820A and 6820B may be similar to the shoulder straps 6702A and 6702B and include one or more layers of padding and/or outer webbing material to provide structural load bearing performance and abrasion resistance. Additionally, the shoulder straps 6702A and 6702B may include a series of multiple loops (a portion of the loops is labeled loop 6716 in Figure 44). It is contemplated that the shoulder straps 6820A and 6820B may include any number of loops 6716 without departing from the scope of the present disclosure. In one example, a series of loops 6716 extend from adjustment buckles 6714A and 6714B to reinforcement patches 6822A and 6822B that extend across the width of shoulder straps 6820A and 6820B.

FIG. 45 depicts an isometric view of another embodiment of a thermal insulation device 8010. In one example, insulation 8010 may be similar to insulation 6010 and include shoulder straps 8702A and 8702B. As shown, insulator 8010 may have a substantially cubic geometry with angled cap assembly 8300 and closure 8311. The thermal insulation 8010 may have a similar construction to the examples described earlier in this disclosure, wherein like reference numerals refer to like features with like functionality. In one example, features identified by the same last three digits and optionally the same letter or alphanumeric suffix may be considered to include similar features and materials and/or methods of construction. It is contemplated that the structures of thermal insulation 8010 may be coupled to each other by any method and/or fastener element, such as those previously described throughout this disclosure, and include, among other things, adhesives, sutures, laser welding and/or or rivets.

In one example, the lower adjustment straps (eg, 8706A) of the shoulder straps 8702A and 8702B can be removably coupled to the second side wall 8507B and the third side wall 8507C. The lower adjustment strap (eg, 8706A) may include a hook 8830 configured to be removably coupled to a D-ring 8832 attached to a sidewall of the insulator 8010 (eg, a third loop) through a webbing loop 8834 side wall 8507C). It is contemplated that the depicted hook 8830 and D-ring 8832 may additionally or alternatively include any detachable attachment mechanism, such as a buckle (similar to one or more of buckles 6714A and 6816 ) or hook and loop fasteners. Additionally or alternatively, the hook 8830 may be configured to be removably coupled directly to the webbing loop 8834 without the use of the D-ring 8832. In one example, the hooks 8830 and D-rings 8832 may be constructed of polymers, metals, alloys, fiber reinforced materials, or ceramics, among others.

FIG. 46 schematically depicts one embodiment of a gap ring fastener 6818 as described with respect to FIG. 44 . In one example, one or more gap ring fasteners 6818 may be used to attach the waist strap 6810 to the lower attachment loops 6718A and 6718B. As shown, the gap ring fastener may include an elongated loop element 9850 having a gap 9852. The gap 9852 can be used to removably couple the gap ring fastener 6818 to the lower attachment loop 6718 (not depicted in FIG. 46 ) by temporarily deforming a portion of the lower attachment loop through the gap 9852 is inserted into the deformed portion and extends the portion once within the hole 9854 of the gap ring fastener 6818. In one example, the gap ring fastener 6818 may be constructed of aluminum. In other embodiments, the gap ring fastener 6818 may be constructed of another metal, alloy, polymer, fiber-reinforced material, or ceramic, or a combination thereof.

In one example, thermal insulation devices such as devices 1010 , 2010 , 3010 , 4010 , 5010 , 6010 , and 8010 described throughout this disclosure may include one or more zipper assemblies, similar to closure 6311 . Alternative embodiments of zipper assemblies may include curved geometries. For example, a zipper can be implemented such that it can be coupled to complex geometries with multiple curved regions, rather than being coupled to a flat surface. Additionally or alternatively, a closure for use with any of the thermal insulation devices described throughout this disclosure may include a zipper having a water-reactive block configured to run along the length of the zipper track position. In this way, the plurality of water reactive resistance bodies can be configured to expand upon exposure to water and provide resistance to the slider body of the zipper mechanism when used to open or close the zipper closure. In one example, the water reactive resistance body may extend continuously along the entire length of the zipper track. The resistance provided by the water-reactive baffle prevents the closure from opening when exposed to water, thereby preventing accidental spillage of fluid, ice, and/or materials located within the thermal insulation.

In another example, a plurality of polymeric barriers may be provided along the length of a zipper track, such as the track of closure 6311. The plastic baffle may be configured to limit movement of the slider body (with or without the presence of water) along the zipper track. In this way, the plurality of polymer blocks can hinder the movement of the slider body along the zipper track. Accordingly, the polymeric barrier may have functionality similar to that of a water-reactive barrier, and may prevent accidental spillage of fluids, ice, and/or materials stored within the thermal insulation.

It is further contemplated that the frame may be incorporated into any of the thermal insulation devices described throughout this disclosure. The frame may be used to distribute the mass and center of gravity of the portable thermal insulation device symmetrically and/or balanced. As such, the frame may be formed from one or more of polymers, fiber reinforced composites, or metals or alloys such as aluminum and titanium.

The thermal insulation devices described throughout this disclosure may be further configured to include one or more storage baffles. It is contemplated that the storage baffle may be constructed using one or more of foam, vacuum insulated panels, metals, alloys, polymers, fiber reinforcements, and ceramics, or combinations thereof. The baffles may be individually sealable waterproof containers, or may be separate and/or divided areas within the interior compartments of the various thermal insulation devices described herein. In one example, the baffles within the insulated storage compartment may be configured to store items of a particular size.

In one example, multiple storage baffles may be used within the thermal insulation. For example, two baffles could be used, such that one baffle is a sealable waterproof baffle and the other baffle is a separate area within an insulated storage compartment other than the sealable waterproof baffle. In one example, the baffle may be removable. Any of the thermal insulation devices described in this disclosure may be configured to receive and store ice such as dry ice, regular ice made from water, one or more ice packs, and/or configured to be filled with a fluid such as water. Removed pouch. The bottom baffles within the insulated storage compartments of the various insulated devices may be specially designed to receive and store ice and/or removable bladders. Such bottom baffles may be lined with and/or fabricated from a conductive material and configured to provide cooling to one or more upper baffles within the insulated storage compartment. In some cases, the upper baffle may also be lined with and/or fabricated from a conductive material, and accordingly may be configured to further distribute the cooling capacity provided by the bottom baffle. Additionally or alternatively, each of the baffles within the insulated storage compartment of the thermal insulation device may be configured to receive and store ice, ice packs, and/or removable bladders.

Since the insulation is configured to store ice made from potable water, the baffles within the insulated storage compartment may be configured to isolate the water from the ice as the ice melts. It may be configured to allow water to flow into the bottom-most reservoir of the interior portion of portable thermal insulation devices such as devices 1010, 2010, 3010, 4010, 5010, 6010, and 8010. The reservoir may include a hose or tube attached thereto that may pass through the interior portion of the portable thermal insulation device to the upper end of the portable thermal insulation device. A hose or tube may extend out of the interior of the insulation from there and may include a one-way nipple at the end portion. The one-way spout may be a drinking spout and may be configured to release water from the internal reservoir when actuated by a user of the thermal insulation device. The reservoir may further include an air pump or bladder that can be manually or electrically pumped to increase the pressure within the reservoir. In the pressurized condition, when actuated, the reservoir can assist in pushing water through the hose or tube and out through the one-way nozzle. It is further contemplated that the water may be filtered prior to its distribution through the drinking nozzle.

In certain embodiments, a perimeter cooling vessel may be positioned adjacent to an insulated storage compartment throughout the insulated device described in this disclosure and configured to provide cooling to the insulated storage compartment. In such embodiments, the perimeter cooling vessel may be configured to receive and store plain ice, dry ice, one or more ice packs and/or removable bladders made of water. The perimeter cooling vessel may be lined or fabricated with a conductive material to achieve cooling distribution to the insulated storage compartment. The peripheral cooling vessel may further be a sealable waterproof vessel.

The perimeter cooling vessel may be secured to a front, bottom, side and/or rear portion of the insulated storage compartment and may be configured to be releasably attached to the insulated storage compartment. In some examples, the perimeter cooling vessel may be rigidly attached to the insulated storage compartment. In the releasably attached configuration, the perimeter cooling vessel can be detached from the portable thermal insulation device.

In some embodiments, the baffles within the insulated storage compartments and the non-insulated storage compartments may be angled to go up and out from the backmost and rearmost portions toward the forwardmost portion and/or of the particular storage compartment. or extending towards the front part. The baffles are so oriented that the center of gravity of the portable thermal insulation device 100 is near the most back and rearmost portions of the device, which, as described above, can be configured to contact the back and shoulders of the wearer during carrying. Thus, the angled baffles may provide a symmetrical weight distribution and center of gravity for the portable thermal insulation device 100 .

An exemplary thermal insulation device may include an outer shell, an inner liner, an insulating layer that floats freely between the outer shell and the inner liner, and a waterproof closure. The top of the housing has a first peripheral circumference and the bottom of the housing has a second peripheral circumference. The first peripheral circumference may be equal to the second peripheral circumference. The closure may be a zipper assembly that includes a plurality of zipper teeth, and the zipper teeth may be formed of plastic or metal. The shell can be made of double-laminated TPU nylon fabric. The inner lining can be made of double-laminated TPU nylon fabric. The insulating layer may be formed from closed cell foam. The insulating layer may be made of a blend of NBR and PVC, and at least a portion of the insulating layer may be composed of a layer of EVA foam. The housing may also include at least one of a strap or a handle. The housing may also include at least one ring for securing the thermal insulation.

An exemplary insulating device may include an outer shell, an inner liner, a closure adapted to seal at least one of the outer shell or the inner liner, and an insulating layer between the outer shell and the inner liner. The closure may have first and second flanges, and the outer liner may be secured to the top surfaces of the first and second flanges, and the inner liner may be secured to the bottoms of the first and second flanges surface. The outer and inner liners can be attached to the closure by polymer welding. The housing may have a first circumference and a second circumference, both of which have an oval shape. The closure may be adapted to act as a barrier to fluids. The closure may be a zipper device that is watertight at pressures up to 7 psi above atmospheric pressure.

An exemplary method of assembling an insulating device may include: forming a liner having an inner vessel; forming an outer shell; forming an insulating layer between the inner liner and the outer shell; and securing a closure configured to prevent A barrier for fluids to seep in and out of the inner vessel, with the closure fixed on the plane and to the outer and inner shells. The outer and inner shells can only be attached to the closure, not to the insulation between the outer shell and the inner liner.

When the closure, outer shell and inner liner are on a horizontal plane, a watertight polymer weld can be formed between the closure and the inner shell and between the closure and the outer shell. The outer shell and inner layer may be formed of TPU nylon material. The closure may have a first flange and a second flange. The outer liner can be secured to the top surfaces of the first and second flanges, and the inner liner can be secured to the bottom surfaces of the first and second flanges.

The method may also include forming the insulating layer from a rectangular shape and rolling the rectangular shape into a cylindrical shape. The top of the insulating layer has a first peripheral circumference and the bottom of the insulating layer has a second peripheral circumference. The first peripheral circumference may be equal to the second peripheral circumference.

Another example insulation may include: an outer shell; an inner liner forming a storage compartment; a foam layer freely floating between the outer and inner liner, the foam layer providing insulation; an opening, The opening extends through the outer and inner layers; and a closure adapted to substantially seal the opening. The closure may be substantially waterproof so as to prevent liquid from flowing out of the opening.

The thermal insulation device may also include an upper wall and a base, the upper wall defining the upper wall circumference, the upper wall length and the upper wall width, and the base defining the base circumference, the base length and the base width. The circumference of the upper wall may be equal to the circumference of the base, and the ratio of the length of the upper wall to the width of the upper wall may be greater than the ratio of the length of the base to the width of the base. In one example, the thermal gain rate of the thermal insulation may be about 1.0-1.5 degF/hr.

Another example method of forming a thermal barrier may include: forming a liner first portion and an outer shell first portion; securing the liner first portion and the outer shell first portion to a sealable closure to form a lid assembly; forming a liner second portion and securing the liner second part to the liner first part to form the liner; forming the shell second part; winding the rectangular foam part to form the first cylindrical foam part and securing the foam base part to the first cylindrical part to forming a foam assembly; inserting the foam assembly into the second shell portion; inserting a liner into the foam assembly; and sewing the shell first portion to the shell second portion. The liner first portion and the outer shell first portion may be welded to the closure. The closure may be provided with at least one flange, and the flange may be secured to the bottom surface of the housing first portion and the top surface of the liner first portion. The foam may float between the second portion of the outer shell and the second portion of the liner.

An example portable insulation device may include: an outer liner; an inner liner forming a storage compartment; and a foam layer between the outer liner and the inner liner. The foam layer may be adapted to provide thermal insulation. The example portable thermal insulation device may also include: an opening extending through one of the outer layer and the inner layer; and a closure device for substantially sealing the opening. The closure may be substantially waterproof.

In one example, a portable cooler may include a hole in the top of the cooler that is opened and closed by a zipper arrangement, allowing access to a cavity within the cooler. This hole prevents any fluid from leaking out of the cooler if the cooler is tipped or in any configuration other than upright. The zipper assembly also prevents any fluids from seeping into the cooler chamber if the cooler is exposed to precipitation, other fluids, or immersed in water.

An example method of assembling an on-hole zipper device configured to be impervious to water or other liquids and fluids may include attaching a waterproof zipper to both the outer shell and the inner liner via material welding. When the zipper mechanism on the hole is sealed, this method can result in the chamber being impermeable to water and other liquids.

In one example, an insulating device can include: an outer shell; an inner liner forming a storage compartment; a foam layer floating between an outer liner and an inner liner, the foam layer providing thermal insulation; an opening extending through the outer and inner layers; a closure adapted to substantially seal the opening, the closure being substantially waterproof to prevent fluid from flowing out of the opening when the thermal insulation is in any orientation. In one example, in the first configuration, the top portion of the housing may have a first peripheral circumference. The housing may include a bottom portion, and in a second configuration different from the first configuration, the bottom portion of the housing may have a second peripheral circumference, and the first peripheral circumference may be equal to the second peripheral circumference. Both the first configuration and the second configuration may be elliptical. In one example, the thermal insulation may include an upper wall and a base, the upper wall may define an upper wall circumference, an upper wall length and an upper wall width, and the base may define a base circumference, a base length and a base width. The circumference of the upper wall may be equal to the circumference of the base, and the ratio of the length of the upper wall to the width of the upper wall may be greater than the ratio of the length of the base to the width of the base. The cold holding time of the thermal insulation device may be about 11 to 20 hours. However, in one example, the cold hold time may be 11 to 15 hours. In another example, the cold hold time can be about 12.24 hours. The heat gain rate of the thermal insulation device can be about 1 to 1.5 degF/hr, and in one particular example, the heat gain rate can be about 1.4 degF/hr. The storage compartment can be configured to hold liquid therein while being inverted for more than 15 minutes. In one particular example, the storage compartment may be configured to hold liquid therein for a time greater than 30 minutes when inverted and half the volume of the storage compartment is filled with liquid.

In one example, the insulating layer can float freely between the outer shell and the inner liner. The insulating layer can be formed of closed cell foam, and the insulating layer can be made of a blend of NBR and PVC. In one example, at least a portion of the insulating layer may be composed of a layer of EVA foam. The closure may be a zipper assembly including a plurality of zipper teeth, and the zipper teeth may be formed of plastic.

In one example, the outer shell and inner liner can be made of double-laminated TPU nylon fabric. The housing may also include at least one of a strap or a handle. The housing may include at least one ring for securing the thermal insulation. The insulating layer may be configured to maintain the interior temperature of the insulating device at a temperature below 50 degrees Fahrenheit for 65 to 85 hours. The closure may be formed with first and second flanges, and the outer liner may be secured to top surfaces of the first and second flanges. A liner can be secured to the bottom surfaces of the first flange and the second flange. The outer and inner liners can be attached to the closure by polymer welding. In one example, the closure may be watertight at pressures up to 2 to 14 psi above atmospheric pressure. Loop patches can also be provided on the thermal insulation.

In another example, an insulating device can include: an outer shell; an inner liner forming a storage compartment; a foam layer floating between an outer liner and an inner liner, the foam layer providing thermal insulation; an opening extending through the outer and inner layers; a closure adapted to substantially seal the opening. The closure may be substantially waterproof so as to prevent liquid from flowing out of the opening when the thermal insulation is inverted for a period of time greater than 15 minutes. The thermal gain rate of the thermal insulation may be about 1.0 to 1.5 degF/hr. The thermal insulation device may include at least one handle. At least one handle can be configured to support a weight of 100 to 300 pounds for 1 to 10 minutes without showing any signs of failure. In one example, the thermal barrier may be configured to withstand a puncture force of 35 pounds to 100 pounds.

An example method of forming a thermal barrier may include: forming a liner first portion and an outer shell first portion; securing the liner first portion and the outer shell first portion to a sealable closure to form a lid assembly; forming a liner second portion and securing the liner second portion to the liner first portion to form the liner; forming the shell second portion; rolling the rectangular foam portion to form the first cylindrical foam portion and securing the foam base portion to the first cylindrical foam portion to forming a foam assembly; inserting the foam assembly into the second shell portion; inserting a liner into the foam assembly; and securing the shell first portion to the shell second portion to form the shell. The method may further include: securing a closure configured as a barrier to prevent fluids from penetrating into and out of the inner vessel; and between the closure and the inner shell when the closure, the outer shell and the inner liner are in a plane and A waterproof polymer weld is formed between the closure and the housing.

In one example, the liner first portion and the outer shell first portion can be secured to the closure. The closure may be provided with at least one flange, and the flange may be secured to the bottom surface of the housing first portion and the top surface of the liner first portion. The foam is free to float between the second part of the outer shell and the second part of the liner. The outer and inner shells are only attached to the closure, not to the insulation between the outer shell and the inner liner. The outer shell may be formed of a TPU nylon material, and the inner liner may be formed of a TPU nylon material. The closure may include a first flange and a second flange. The outer liner can be secured to the top surfaces of the first and second flanges, and the inner liner can be secured to the bottom surfaces of the first and second flanges. The top of the insulating layer may have a first peripheral circumference. The bottom of the insulating layer may have a second peripheral circumference. The first peripheral circumference may be equal to the second peripheral circumference.

In one example, an insulating device can include: an outer shell defining a side wall; an inner liner forming a storage compartment; an insulating layer positioned between the outer shell and the inner liner, the An insulating layer provides thermal insulation of the storage compartment; an opening extending through the outer shell and the inner liner; and a closure adapted to substantially seal the opening, the closure being substantially waterproof for protection in the compartment The thermal device prevents liquid from flowing out of the opening in any orientation. The thermal insulation may include a vertically extending forward facing surface, and the closure may be located on the forward facing surface. The cross-section of the thermal insulation may be approximately pentagonal in the deployed position, and the cross-section of the thermal insulation may be approximately trapezoidal in the deployed position. The insulating device may also include a base, and the insulating layer may insulate the base. The base may also include additional thermal insulation.

The thermal insulation may also include a lower folded portion configured to cover the closure. The lower folded portion includes a first section and a second section, and wherein the first section is free of thermal insulation and the second section contains thermal insulation. The lower folded portion may be at least partially free of foam. The lower folded portion may be configured to be secured to the side wall. The lower folded portion may include at least one hook and the side wall may include at least one loop. The hook may be configured to engage the loop to secure the lower folded portion to the side wall. The lower folded portion may be secured to the side wall, and the lower folded portion may extend at least partially in a substantially horizontal direction. The lower folded portion may define a first width, and the closure extends across at least 95% of the first width. The lower folded portion may also include a handle configured to be grasped by a user when the lower folded portion is secured to the side wall.

The insulating layer may comprise a foam material. The insulating layer may include a first portion and a second portion, and the second portion may be formed thicker than the first portion. The insulating layer may be formed at least partially in a T-shape. The insulating layer may be formed at least partially from the first rectangle and the second rectangle, and the first rectangle may have a larger area than the second rectangle. The first rectangle may have a first rectangle width and the second rectangle may have a second rectangle perimeter. The width of the first rectangle may approximate the perimeter of the second rectangle. The second rectangle may extend into the lower folded portion. The insulating layer may have a first height and a second height, and the first height may be greater than the second height. A substantial portion of the insulating layer may extend to the second height.

A method of forming an insulating device may include: forming an inner liner, the inner liner defining a storage compartment; forming an outer shell, the outer shell defining a side wall; placing an insulating layer between the outer shell and the inner liner, the insulating layer providing protection against Insulation of storage compartments; placement of openings in liner and shell; and placement of closures between liner and shell. The closure may be adapted to substantially seal the opening, and the closure may be substantially waterproof to prevent liquid from flowing out of the opening when the thermal insulation is in any orientation. The method may also include forming a lower folded portion configured to cover the closure to provide the lower folded portion with a first section and a second section. The first section may be free of thermal insulation, while the second section may contain thermal insulation. The lower folded portion may be at least partially free of foam. The lower folded portion may be configured to be secured to the side wall. The method may further include: forming the insulating layer at least partially in a T shape; forming the insulating layer at least partially in the first rectangle and the second rectangle; and forming the first rectangle having a larger area than the second rectangle. The method may further include: extending the second rectangle into the lower folded portion; and providing an insulating layer on the base and an additional insulating layer along the base.

In another example, an insulating device can include: an outer shell defining a sidewall; an inner liner forming a storage compartment; and an insulating layer between the outer shell and the inner liner. The insulating layer may provide thermal insulation of the storage compartment. The thermal insulation may include an opening configured to allow access to the storage compartment, and a closure adapted to substantially seal the opening. The thermal insulation may include a bonding material, and the bonding material may be placed over the joint between the liner and the outer shell. The adhesive material can be stitched to the insulation, and the stitches can create openings in the outer shell to vent air trapped between the insulation and the outer shell. The adhesive material may form at least one strip for holding the thermal insulation. The adhesive material may include a first folded portion and a second folded portion attached to the housing, and the second folded portion may form a strap.

From the front view, the thermal insulation device may be approximately trapezoidal; from the side view, the thermal insulation device may be approximately conical. In one example, the insulator increases from 0°F to 50°F over a duration of 70 hours or longer when filled with 0.52 pounds of ice per quart in terms of capacity of the insulator.

The closure may be substantially waterproof so as to prevent liquid from flowing out of the opening when the thermal insulation is in any orientation. In one example, the insulation can be configured to stand upside down for 15 minutes without any water escaping or leaving the storage compartment. The closure may be configured to remain in the open position when the closure is not sealed. The closure may be a zipper. In one example, the closure extends at least 80% of the length of the thermal insulation when measured along the closure. The length of the closure may be longer than the length of the bottom of the thermal insulation, and the length of the closure is at least 5% longer than the length of the bottom of the thermal insulation. The thermal insulation may include a vertically extending forward facing surface, and the closure may be located on the forward facing surface. The handle may be located on the rear facing surface opposite the forward facing surface.

In an example thermal insulation device, the thermal insulation layer may comprise a foam material. The insulating layer may include a first portion and a second portion, and the second portion may be formed thicker than the first portion. The insulating layer may be formed at least partially from the first rectangle and the second rectangle, and the first rectangle may have a larger area than the second rectangle. The insulating layer may have a first height and a second height, and the first height may be greater than the second height. In one example, a substantial portion of the insulating layer may extend to the second height. Additionally or alternatively, the front portion of the insulating layer may extend to the second height and the rear portion of the insulating layer may extend to the first height. The thermal insulation may include a base, and the thermal insulation layer may insulate the base. The base may also include additional or separate thermal insulation. In one example, the insulating layer may cover 80% or more of the liner (which covers the storage compartment), or the insulating layer may cover 90% or more of the liner (which covers the storage compartment) many.

In another example, a method of forming an insulating device can include: forming an inner liner, the inner liner defining a storage compartment; forming an outer shell, the outer shell defining a side wall; placing an insulating layer between the outer shell and the inner liner, The insulating layer provides insulation of the storage compartment; an opening is placed in the liner and the outer shell; a closure is placed between the inner liner and the outer shell, the closure being adapted to substantially seal the opening, the closure being substantially waterproof so as to prevent liquid from flowing out of the opening when the insulation is in any orientation. The method may further include forming the thermal insulation layer at least partially in the first rectangle and the second rectangle, and forming the first rectangle having a larger area than the second rectangle. The method may also include: providing an insulating layer on the base; and providing an additional insulating layer along the base.

An example insulating device may include: an outer shell defining a first side wall; an inner liner forming a storage compartment; an insulating layer between the outer shell and the inner liner, the insulating layer Provides insulation for storage compartments. The outer shell and the inner liner can define an opening, and the opening can be configured to allow access to the storage compartment. The closure may be adapted to substantially seal the opening, and the closure may be substantially waterproof to prevent liquid from flowing out of the opening when the thermal insulation is in any orientation. The housing may include a second side wall and a third side wall, and the opening may extend through the first side wall, the second side wall, and the third side wall. The thermal insulation device may be in the shape of a cuboid. The liner and the outer shell can form a joint, and the joint can include a vent to gas trapped between the liner and the outer shell. The housing may include one or more handles, and an air vent may be formed near the location of the one or more handles. The closure may be substantially waterproof to prevent fluid from flowing out of the opening if the insulation is dropped from a height of six feet.

The thermal insulation device may also include a cover assembly and a body assembly. The cover assembly and body assembly may together form the liner, insulation and outer shell. The cover assembly may include at least a portion of the thermal barrier. The cover assembly may also include a handle and a reinforcement layer that is more rigid than the inner liner, thermal insulation layer, and outer shell.

The outer shell may define a bottom wall extending in a first plane, and the liner may be secured to the outer shell in a second plane extending perpendicular to the first plane. The liner may be formed from a first sheet and a second sheet, and the first sheet is joined to the second sheet by welding to define a seam, and the seam may be covered with seam tape. In an alternative example, the liner may be formed by injection molding. The closure may be a zipper and may be substantially waterproof. The zipper may include a pull tab, and the pull tab may be formed of cloth, thread, or cord. In certain instances, the temperature of the thermal barrier is increased from 0°F to 10°F over a duration of 0.5 hours to 1.5 hours, and the temperature of the thermal barrier is increased from 10°F to 50°F over a duration of 22 hours to 28 hours. °F, and the temperature of the insulation is increased from 0 °F to 50 °F over a duration of 24 hours to 30 hours.

An example method may include: forming a body assembly by forming a lower shell, placing a lower thermal barrier into the lower shell, and securing a lower liner portion to the lower shell; forming a body assembly having an upper shell, an upper liner portion, and both. and attaching the lid assembly to the body assembly by securing the closure between the lid assembly and the body assembly and by securing an adhesive material to the body assembly and the lid assembly. An insulating layer may float between the lower shell and the lower liner portion. The adhesive material may be formed of nylon, and the adhesive material may be sewn to the body assembly and the lid assembly. The cover assembly can also be welded to the body assembly. Additionally, the cover assembly may also be formed with a handle and a reinforcement layer that is more rigid than the inner liner, thermal insulation layer, and outer shell. In some instances, the lower liner portion may be formed by injection molding.

The lower liner portion may be fixed to the lower shell by welding. The weld may be formed by clamping the lower shell to the lower liner portion with the top U-shaped portion, the plate portion and the bottom U-shaped portion and applying current through the top U-shaped portion, the plate portion and the bottom U-shaped portion. Current may be applied in a first direction through the top U-shaped portion, plate portion, and bottom U-shaped portion to weld the first side, and current may be applied in a second direction to weld the second side.

An example insulating device may include: an outer shell defining a first side wall; an inner liner forming a storage compartment; an insulating layer between the outer shell and the inner liner, the insulating layer Provides insulation for storage compartments. Example insulation may also include a back panel support structure externally coupled to the housing. The outer shell and the inner liner can define an opening, and the opening can be configured to allow access to the storage compartment. The closure may be adapted to substantially seal the opening, and the closure may be substantially waterproof to prevent liquid from flowing out of the opening when the thermal insulation is in any orientation. The housing may include second and third side walls defining side portions of the insulator, and a fourth side wall defining a back portion of the insulator. The back panel support structure may be externally coupled to the fourth side wall. The opening may extend through at least a portion of the first side wall, the second side wall, the third side wall, and the fourth side wall. The thermal insulation may also include shoulder straps attached to the back panel support structure. The thermal insulation device may be in the shape of a cuboid. The liner and the outer shell can form a joint, and the joint can include a vent to gas trapped between the liner and the outer shell. The housing may include one or more handles, and an air vent may be formed near the location of the one or more handles. The closure may be substantially waterproof to prevent fluid from flowing out of the opening if the insulation is dropped from a height of six feet.

The thermal insulation device may also include a cover assembly and a body assembly. The cover assembly and body assembly may together form the liner, insulation and outer shell. The cover assembly may include at least a portion of the thermal barrier. The cover assembly may also include a handle and a reinforcement layer that is more rigid than the inner liner, thermal insulation layer, and outer shell.

The outer shell may define a bottom wall extending in a first plane, and the liner may be secured to the outer shell in a second plane extending perpendicular to the first plane. The liner may be formed from a first sheet and a second sheet, and the first sheet is joined to the second sheet by welding to define a seam, and the seam may be covered with seam tape. In an alternative example, the liner may be formed by injection molding. The closure may be a zipper and may be substantially waterproof. The zipper may include a pull tab, and the pull tab may be formed of cloth, thread, or cord. In certain instances, the temperature of the thermal barrier is increased from 0°F to 10°F over a duration of 0.5 hours to 1.5 hours, and the temperature of the thermal barrier is increased from 10°F to 50°F over a duration of 22 hours to 28 hours. °F, and the temperature of the insulation is increased from 0 °F to 50 °F over a duration of 24 hours to 30 hours.

An example method may include: forming a body assembly by forming a lower shell, placing a lower thermal barrier into the lower shell, and securing a lower liner portion to the lower shell; forming a body assembly having an upper shell, an upper liner portion, and both. The cover assembly of the upper insulation layer between. The method may further include forming a back panel support structure, joining the back panel support structure to the back portion of the body assembly, and by securing a closure between the lid assembly and the body assembly and by securing an adhesive material to the body assembly and the cover assembly to join the cover assembly to the body assembly. The method may also include forming the shoulder straps and joining the shoulder straps to the back panel support structure. An insulating layer may float between the lower shell and the lower liner portion. The adhesive material may be formed of nylon, and the adhesive material may be sewn to the body assembly and the lid assembly. The cover assembly can also be welded to the body assembly. Additionally, the cover assembly may also be formed with a handle and a reinforcement layer that is more rigid than the inner liner, thermal insulation layer, and outer shell. In some instances, the lower liner portion may be formed by injection molding.

The lower liner portion may be fixed to the lower shell by welding. The weld may be formed by clamping the lower shell to the lower liner portion with the top U-shaped portion, the plate portion and the bottom U-shaped portion and applying current through the top U-shaped portion, the plate portion and the bottom U-shaped portion. Current may be applied in a first direction through the top U-shaped portion, plate portion, and bottom U-shaped portion to weld the first side, and current may be applied in a second direction to weld the second side.

An example insulator pack may include a shell having a cuboid shape and defining a first side wall that defines a front portion of the insulator pack. The second and third side walls may define side portions of the insulator pack, and the fourth side wall may define a back portion of the insulator pack. The insulated backpack may additionally include: an inner liner forming a storage compartment; an insulating layer located between the outer shell and the inner liner, the insulating layer providing insulation of the storage compartment. The example insulator backpack may also include a back panel support structure externally attached to the outer shell. Example insulation backpacks may additionally include shoulder straps coupled to the back panel support structure. The outer shell and the inner liner can define an opening, and the opening can be configured to allow access to the storage compartment. The closure may be adapted to substantially seal the opening, and the closure may be substantially waterproof to prevent liquid from flowing out of the opening when the thermal insulation is in any orientation. The back panel support structure may be externally coupled to the fourth side wall. The opening may extend through at least a portion of the first side wall, the second side wall, the third side wall, and the fourth side wall. The liner and the outer shell can form a joint, and the joint can include a vent to gas trapped between the liner and the outer shell. The housing may include one or more handles, and an air vent may be formed near the location of the one or more handles. The closure may be substantially waterproof to prevent fluid from flowing out of the opening if the insulation is dropped from a height of six feet.

The invention has been disclosed above and in the accompanying drawings with reference to various examples. The purpose served by this disclosure, however, is to provide examples of the various features and concepts related to the invention, rather than to limit the scope of the disclosure. Those skilled in the relevant art will recognize that various changes and modifications of the above-described examples can be made without departing from the scope of the present invention.

Claims (29)

1. An insulated unit backpack comprising:

a housing having a cubic shape, the housing further comprising:

a first sidewall defining a front portion of the thermal isolation device backpack; and

a second sidewall and a third sidewall defining a side portion of the thermal isolation device backpack, and a fourth sidewall defining a back portion of the thermal isolation device backpack;

a liner forming a storage compartment;

an insulation layer positioned between the outer shell and the inner liner, the insulation layer providing insulation to the storage compartment;

a back panel support structure externally coupled to the outer shell;

a shoulder strap coupled to the back panel support structure;

an opening configured to allow access to the storage compartment; and

a closure adapted to substantially seal the opening, the closure being substantially waterproof so as to prevent liquid from flowing out of the opening when the insulating device is in any orientation,

wherein the opening extends through at least a portion of the first sidewall, the second sidewall, the third sidewall, and the fourth sidewall.

2. The insulated unit backpack of claim 1, wherein the back panel support structure is externally coupled to the fourth side wall.

3. The insulated unit backpack of claim 1, further comprising a waist belt removably coupled to the fourth side wall.

4. The insulated unit backpack of claim 1, wherein the back panel support structure comprises an outer layer and an inner layer, and wherein the outer layer of the back panel support structure comprises compression molded ethylene vinyl acetate copolymer.

5. The insulated unit backpack of claim 1, wherein the inner liner and the outer shell form a joint, and wherein the joint includes a vent to gas.

6. The insulated unit backpack of claim 1, wherein the housing includes one or more handles, and wherein an exhaust port is formed adjacent to the one or more handles.

7. The insulated unit backpack of claim 1, wherein the enclosure is substantially waterproof so as to prevent liquid from flowing out of the opening when the insulated unit is completely filled with water and falls from a distance of six feet.

8. The insulated unit backpack of claim 1, wherein the outer shell defines a bottom wall extending in a first plane, and wherein the liner is secured to the outer shell in a second plane extending perpendicular to the first plane.

9. The insulated unit backpack of claim 1, wherein the inner liner is formed from a first piece and a second piece, and wherein the first piece is joined to the second piece by welding to define a seam, and wherein the seam is covered by a seam tape.

10. The insulated unit backpack of claim 1, wherein the inner liner is formed by injection molding.

11. The thermally insulated unit backpack of claim 1, wherein the enclosure is a zipper and is substantially waterproof, and wherein the zipper includes a pull tab formed of a cloth, wire, or cord.

12. The insulated unit backpack of claim 1, further comprising a lid assembly and a body assembly.

13. The insulated unit backpack of claim 12, wherein the lid assembly and the body assembly together form the inner liner, the insulation layer, and the outer shell.

14. The insulated unit backpack of claim 12, wherein the cover assembly includes at least a portion of the insulation layer.

15. The insulated unit backpack of claim 12, wherein the cover assembly includes a handle and a reinforcement layer, the reinforcement layer being more rigid than the inner liner, the insulation layer, and the outer shell.

16. The insulated unit backpack of claim 1, wherein the insulation layer floats between the inner liner and the outer shell.

17. The insulated unit backpack of claim 1, wherein the insulation layer is attached to the inner liner or the outer shell.

18. An insulation device comprising:

a housing defining a first sidewall;

a liner forming a storage compartment;

an insulation layer positioned between the outer shell and the inner liner, the insulation layer providing insulation to the storage compartment;

a back panel support structure externally coupled to the outer shell;

an opening configured to allow access to the storage compartment; and

a closure adapted to substantially seal the opening, the closure being substantially waterproof so as to prevent liquid from flowing out of the opening when the insulating device is in any orientation.

19. The thermal isolation device of claim 18, wherein the first sidewall defines a front portion of the thermal isolation device, wherein the housing further comprises a second sidewall and a third sidewall, the second sidewall and the third sidewall defining side portions of the thermal isolation device; and

a fourth sidewall defining a back portion of the insulation device, and wherein the back panel support structure is externally coupled to the fourth sidewall.

20. The thermal isolation device of claim 19, wherein the opening extends through at least a portion of the first sidewall, the second sidewall, the third sidewall, and the fourth sidewall.

21. The thermal isolation device of claim 18, further comprising a shoulder strap coupled to the back panel support structure.

22. The thermal insulation of claim 18, wherein the thermal insulation is in the shape of a cuboid.

23. The thermal isolation device of claim 18, wherein the inner liner and the outer shell form a joint, and wherein the joint includes a vent to gas.

24. The thermal isolation device of claim 18, wherein the housing includes one or more handles, and wherein a vent is formed adjacent the one or more handles.

25. The thermal insulation apparatus of claim 18, wherein the liner is formed from a first piece and a second piece, and wherein the first piece is joined to the second piece by welding to define a seam, and wherein the seam is covered by a seam tape.

26. The thermal insulation apparatus of claim 18, wherein the inner liner is formed by injection molding.

27. A method, comprising:

forming a body assembly by forming a lower outer shell, placing a lower insulation layer into the lower outer shell, and securing a lower liner portion to the lower outer shell;

forming a lid assembly having an upper outer shell, an upper liner portion, and an upper insulation layer therebetween;

forming a back panel support structure and joining the back panel support structure to a back portion of the body assembly; and

the closure assembly is joined to the body assembly by securing a closure between the closure assembly and the body assembly and by securing an adhesive material to the body assembly and the closure assembly.

28. The method of claim 27, further comprising:

forming a shoulder strap and joining the shoulder strap to the back panel support structure.

29. The method of claim 27, wherein the insulation layer floats between the lower outer shell and the lower liner portion.

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