Cooler assembly and method of making same

Abstract

A cooler assembly includes an outer shell and an inner shell configured together with an inner core under vacuum pressure therebetween. The cooler assembly also may include structural support members arranged between the inner and outer shells to support the shells, to keep the shells at a desired spacing, and to provide mechanical support therebetween to help prevent shell deformations during the vacuum pressure process and during use. In this way, the cooler assembly may include a vacuumed insulation core.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 749,857 filed January 27, 2025, the entire contents of which are hereby fully incorporated herein by reference for all purposes.FIELD OF THE INVENTION

[0002] The present invention relates to coolers, including a cooler assembly with an outer shell and an inner shell configured under vacuum pressure and a structural support core therebetween.BACKGROUND

[0003] Coolers are used throughout the world to keep food and beverages cool for enjoyment. Coolers also are used to keep other items such as medicine, organs, and other items cool during transport of such items. However, coolers available on the market often do not provide adequate cooling over an adequate time frame for some uses.

[0004] Some such coolers have attempted to implement inner cores under vacuum pressure to reduce the heat transfer mechanism between the environment outside the cooler and that within. However, such attempts have been unable to reach an adequately low vacuum pressure due compression deformations within the cooler’s core during the vacuum pressure process.

[0005] Accordingly, there is a need for a cooler assembly with support mechanisms within the inner core to support the cooler during the vacuum pressure process.SUMMARY

[0006] According to a first aspect, one or more embodiments of a cooler assembly are provided herein. In some embodiments, the cooler assembly comprises a first shell wall aligned with a second shell wall forming a shell inner volume therebetween, the first shell wall including a first shell inner surface facing the shell inner volume and the second shell wall including a second shell inner surface facing the shell inner volume; and at least one support member configured within the shell inner volume and extending from the first shell inner surface to the second shell inner surface to provide support therebetween; and wherein the shell inner volume is placed under vacuum pressure.

[0007] In other embodiments, the at least one support member is configured to prevent deformation of the first shell wall and / or the second shell wall when the shell inner volume is placed under vacuum pressure.

[0008] In other embodiments, the at least one support member includes a plurality of support members arranged in a matrix.

[0009] In other embodiments, the matrix comprises at least one horizontal series of support members and at least one vertical series of support members.

[0010] In other embodiments, the at least one support member includes two or more at least one support members coupled to one another to form a support lattice.

[0011] In other embodiments, the at least one support member includes at least one X-shaped support member.

[0012] In other embodiments, a top two tips of the at least one X-shaped support member abut against the first shell inner surface and a bottom two tips of the X-shaped support member abut against the second shell inner surface.

[0013] In other embodiments, the at least one support member includes a cellular beam.

[0014] In other embodiments, the cellular beam includes at least one hole passing through the cellular beam.

[0015] In other embodiments, the first shell inner surface and second shell inner surface are opposing one another.

[0016] In other embodiments, the cooler assembly further comprises a valve leading into the shell inner volume for placing the shell inner volume under vacuum pressure.

[0017] According to another aspect, a method of making a cooler assembly including an inner core under vacuum pressure includes aligning a first shell wall with a second shell wall to form a shell inner volume therebetween, the first shell wall including a first shell inner surface facing the shell inner volume and the second shell wall including a second shell inner surface facing the shell inner volume; configuring at least one support member within the shell inner volume and extending from the first shell inner surface to the second shell inner surface to provide support therebetween; and placing the shell inner volume under vacuum pressure.

[0018] In other embodiments, the configuring the at least one support member within the inner volume includes configuring a plurality of support members in a matrix.

[0019] In other embodiments, the matrix comprises at least one horizontal series of support members and at least one vertical series of support members.

[0020] In other embodiments, the at least one support member includes two or more at least one support members coupled to one another to form a support lattice.

[0021] In other embodiments, the at least one support member includes at least one X-shaped support member.

[0022] In other embodiments, a top two tips of the at least one X-shaped support member are configured to abut against the first shell inner surface and a bottom two tips of the X-shaped support member are configured to abut against the second shell inner surface.

[0023] In other embodiments, the at least one support member includes a cellular beam.

[0024] In other embodiments, the first shell inner surface and second shell inner surface are aligned to be opposing one another.

[0025] In other embodiments, the method further includes using a valve leading into the shell inner volume to place the shell inner volume under vacuum pressure.

[0026] The presently disclosed cooler assembly is more fully described in the detailed description below.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

[0028] FIG. 1 shows a perspective view of a shell assembly according to exemplary embodiments hereof;

[0029] FIG. 2 shows a sectional view of a shell assembly according to exemplary embodiments hereof;

[0030] FIG. 3 shows an exploded view of a shell assembly according to exemplary embodiments hereof;

[0031] FIG. 4 shows aspects of a core assembly according to exemplary embodiments hereof;

[0032] FIG. 5 shows aspects of a core assembly within a shell assembly according to exemplary embodiments hereof;

[0033] FIGS. 6-9 show sectional views of a shell assembly and inner core according to exemplary embodiments hereof;

[0034] FIG. 10 shows aspects of an inner core according to exemplary embodiments hereof;

[0035] FIG. 11 shows aspects a support member according to exemplary embodiments hereof;

[0036] FIG. 12 shows aspects of a plurality of support members according to exemplary embodiments hereof;

[0037] FIGS. 13-14 show aspects of a support member according to exemplary embodiments hereof; and

[0038] FIG. 15 shows aspects of a lid assembly according to exemplary embodiments hereof;DETAILED DESCRIPTION OF THE INVENTION

[0039] In general, and according to exemplary embodiments hereof, a cooler assembly and method of manufacture is provided. In some embodiments, the cooler assembly includes an outer shell and an inner shell configured together under vacuum pressure. The cooler assembly also may include structural support members arranged between the inner and outer shells to support the shells, to keep the shells at a desired spacing, and to provide mechanical support therebetween to help prevent shell deformations due to the vacuum pressure. In this way, the cooler assembly may include a vacuumed insulation core.

[0040] As is known, coolers operate by minimizing the heat transfer between the outer environment and the cooler’s internal cooler compartment. As will be described herein, the inventive cooler assembly minimizes this heat transfer by providing a vacuum insulation core. The vacuum insulation core may include internal structure support members to counteract the forces imparted onto the cooler due the vacuum pressure process and during use of the cooler assembly.

[0041] FIG. 1 shows a perspective view of a cooler assembly 10, FIG. 2 shows a generalized block diagram of a front sectional view of the cooler assembly 10 of FIG. 1 taken along the cutlines A-A, and FIG. 3 shows an exploded view of the block diagram of FIG. 2. The back side of the assembly 10 in FIGS. 2-3 has been made transparent for clarity.

[0042] In some embodiments, as shown in FIGS. 1-3, the cooler assembly 10 (also referred to herein as simply the assembly 10) generally includes a shell assembly 100 formed of an outer shell 102, an inner shell 104, and a structural support core 200 therebetween. The shell assembly 100 defines an inner cooler compartment 12 into which items may be placed to keep them cold. The cooler assembly 10 also includes a lid 300 to seal the cooler compartment 12. As will be described in other sections, the inner volume 105 of the shell assembly 100 (between its inner and outer shells 102, 104) is pressurized under vacuum, and the structural support core 200 provides thermal insulation as well as mechanical support to the shell walls (e.g., to the inner and outer shells 102, 104 under pressure). The assembly 10 also may include other elements and components as necessary to fulfill its functionalities.

[0043] As is known, heat transfer may typically occur in three ways: convection, conduction, and / or radiation. Heat convection involves a process by which heat is transferred by movement of a heated fluid, e.g., such as air or water. In this case, heat is transferred from one place to another through the movement of fluids. For example, hot air rising from a fire is a form of convection. Heat conduction, on the other hand, is the transfer of energy (e.g., heat) through direct physical contact of matter or particles. For example, heat may be transferred from a hot iron to clothing by pressing the hot iron onto the clothing to remove its wrinkles. Thermal radiation involves the transfer of heat energy through space via electromagnetic waves.

[0044] Given the above, it is seen that both convection and conduction generally rely on the presence of molecules, e.g., on the movement of molecules for conduction or the transfer of energy between molecules for conduction. Given this, removing the molecules (e.g., by creating a vacuum) may eliminate (or at least significantly reduce) the fundamental heat transfer mechanisms for both convection and conduction heat transfers within the cooler shell 100.

[0045] Accordingly, in some embodiments, the method of the cooler assembly 10 includes creating a vacuum in the cooler’s inner volume 105 between the inner and outer shells 102, 104. That is, by removing the molecules (e.g., the air) from the inner volume 105, the processes of heat convection and / or heat conduction may be eliminated (or at least significantly reduced).

[0046] In some embodiments, the inner volume 105 is pressurized under vacuum thereby creating a vacuum insulation between the inner and outer shells 102, 104. In some embodiments, the support core 200 within the inner volume 105 is therefore also under vacuum pressure.

[0047] In some embodiments, as shown in FIGS. 1 and 2, the shell 100 includes an outer shell 102, an inner shell 104, and a support core 200 therebetween. The inner shell 104 preferably fits symmetrically within the outer shell 102 such that the upper portions of the shells 102, 104 may be generally aligned. The inner spacing between the inner and outer shells 102, 104 is preferably generally uniform throughout the volume between the shells 102, 104, however, depending on the application and ultimate shape of the assembly 10, this may not necessarily be the case in all scenarios.

[0048] In some embodiments, the outer and inner shells 102, 104 comprise aluminum 1050A, aluminum alloys 6060, 6061, 6065, and / or other suitable materials.

[0049] In some embodiments, with the inner and outer shells 102, 104 configured and aligned as shown in FIG. 2, and with the core 200 positioned within the inner volume 105 between the shells 102, 104, the shells 102, 104 may be sealed to one another, e.g., at their upper portions, using a shell sealing member 106. This sealing may enable the shell’s inner volume 105 to be placed under vacuum pressure. The sealing member 106 may include a section of material extending between the outer and inner shells 102, 104 at an interface between the shells 102, 104, e.g., along the top portion of the shell assembly 100. In some embodiments, the outer and inner shells 102, 104 each include upper flanges or other surfaces over which the sealing member 106 may extend and engage to thereby seal the interface closed. In some embodiments, the sealing member 106 and the outer and inner shells 102, 104 may be bonded together using cold welding, crimping, and / or other suitable bonding techniques. Once sealed, the shell’s inner volume 105 and the support core 200 therewithin may be placed under vacuum pressure as described in other sections.

[0050] Note that while the sealing member 106 is shown as configured with the upper portions of the inner and outer shells 102, 104, it is understood that the sealing member 106 may be configured at other locations of the assembly 10 depending on the application and ultimate shape of the assembly 10 and the resulting configuration and shape of the shells 102, 104.

[0051] In some embodiments, as shown in FIG. 2, the outer shell 102 includes an outer surface 108 and an inner surface 110, wherein the outer surface 108 faces outward from the outer shell 102 and the inner surface 110 faces the core 200. Similarly, the inner shell 104 includes an outer surface 112 and an inner surface 114, wherein the outer surface 112 faces outward from the inner shell 104 (e.g., into the inner compartment 12) and the inner surface 114 faces the core 200. As such, the outer shell’s outer surface 108 and the inner shell’s outer surface 112 are opposite one another while the outer shell’s inner surface 110 and the inner shell’s inner surface 114 are opposing across the core 200.

[0052] FIG. 4 shows the core 200 isolated from the inner and outer shells 102, 104 for clarity.

[0053] In some embodiments, as shown in FIG. 4, the core 200 includes an outer surface 202 and an inner surface 204. As shown in FIG. 2, when configured between the inner and outer shells 102, 104, the core’s outer surface 202 may generally abut the outer shell’s inner surface 110, and the core’s inner surface 204 may generally abut the inner shell’s inner surface 114. As described in other sections, the core 200 may be formed by configuring the outer shell 102 with the inner shell 104 and then filling the volume between the inner and outer shells 102, 104 with one or more materials (e.g., insulation materials(s)), and as such, the core’s inner and outer surfaces 202, 204 may be at least partially formed of the insulation materials during this process. In other embodiments, the core 200 (or any portion thereof) may be formed outside of the inner and outer shells 102, 104 and then configured between the shells 102, 104 during the manufacturing process. This will be described in detail in other sections.

[0054] In some embodiments, as shown in FIG. 4, the core 200 includes one or more support members 206 extending from its outer surface 202 to its inner surface 204. Each support member 206 may include a first end 208 positioned at or near the core’s outer surface 202 and a second end 210 positioned at or near the core’s inner surface 204.

[0055] As shown in FIG. 5, when the core is configured between the inner and outer shells 102, 104, the support members 206 may generally abut and extend between the outer shell’s inner surface 110 and the inner core’s inner surface 114. For example, a support member’s first end 208 may preferably abut the outer shell’s inner surface 110, and the support member’s second end 210 may preferably abut the inner shell’s inner surface 114. As such, the support member 206 may extend (preferably linearly) between the surfaces 110, 114 to provide mechanical support thereto and to keep the surfaces 110, 114 at a desired spacing even as the volume 105 between the inner and outer shells 102, 104 may be placed under vacuum pressure. In this way, the shell assembly 100 may withstand the pressure difference between the inside and outside of the shell 100 without deforming or distorting (e.g., imploding) due to the vacuum therein. Additionally, greater vacuum pressure may be achieved due to the reinforced shell 100 being able to withstand greater pressure deltas, thereby improving the shell’s vacuum insulation capabilities and resulting specifications. Also, the support members 206 may enable the distance between the outer and inner shells 102, 104, and therefore the size of the inner volume 105, to be increased, thereby increasing the vacuum insolation properties.

[0056] FIG. 6 shows a front sectional view of the cooler assembly 10 of FIG. 1 taken along the cutlines B-B, and FIG. 7 shows a side view of the assembly 10 with the side wall made transparent to provide visibility of the support members 206 within. FIG. 8 shows a top view of the assembly 10 with the upper shell sealing member 106 made transparent to show the support members 206 from above.

[0057] In some embodiments, as shown in FIGS. 6, 7, and 8, the support members 206 may comprise X-shaped brace members. While FIG. 7 shows a 3x3 matrix or array of support members 206 arranged generally uniformly within the side of the cooler assembly 10, it is understood that this is for demonstration and that any number of support members 206 may be arranged in any positions within the core 200 as desired. It also is understood that while FIGS. 6-8 depict the support members 206 as oriented generally horizontally, it is understood that this is for demonstration and that the support members 206 may be oriented in other orientations such as vertically and / or at offset angles, e.g., depending on where the support members 206 may be positioned within the side of the assembly 10 and / or the application and shape of the cooler assembly 10. It also is understood that the support members 206 may not necessarily be arranged uniformly, and that the orientation of the support members 206 need not match one another. For example, different support members 206 may be oriented depending on the overall form of the cooler assembly 10 and / or depending on the shape and form of their location within the side of the assembly 10, e.g., in a linear side portion or in a curved corner portion. In addition, while FIGS. 6-8 depict the support members 206 as being generally equal in size and shape, the size and shape of the support members 206 need not necessarily match.

[0058] In some embodiments, the support members 206 may be formed as other shapes, e.g., depending on the shape and form of the cooler assembly 10 and / or the location of the support members 206 within the side of the assembly 10 to best support the inner and outer shells 102, 104 of said shape or form. For example, a shape, size, and orientation of a support member 206 along a flat sidewall may be different than the shape, size, and orientation of a support member 206 in an internal corner or other contour of the assembly 10.

[0059] For example, in some embodiments, the support members 206 may include singular posts or blocks. In other embodiments, the support members 206 may be formed as “knee knockers”. In other embodiments, the support members 206 may be formed as spiders. In other embodiments, the support members 206 may be formed as a cellular beam bracing assembly designed to counteract the ripple effect within the inner volume 105 under vacuum pressure.

[0060] In some embodiments, the support members 206 may be formed as a combination of various shapes, e.g., as an X-shaped member within a block, as an X-shaped member configured with posts on either side, etc. In any event, it is understood that the support members 206 may be formed as any shapes and / or forms and / or any combinations thereof.

[0061] In some embodiments, the material(s) used to form the support members 206 are chosen to minimize heat transfer between the inner and out shells 102, 104 via the support members 206. For example, the support members 206 may be formed of polypropylene or other suitable materials. The support members 206 may be extruded, molded, or otherwise formed.

[0062] In some embodiments, the support members 206 may include perforations (e.g., micro perforations) to enhance the vacuum pressure process by enabling molecules from within the support members 206 to be drawn out as well.

[0063] In some embodiments, as shown in FIG. 4, one or more support members 206 are configured together (e.g., coupled together during or after the manufacturing process) so that the support members 206 may be implemented within the shell’s inner volume 105 together as one or more a single unit each comprising a plurality of support members 206. For example, the support members 206 may be held within a lattice structure 212 or other type of structure (e.g., an inner shell or skeleton) that supports the support members 206 together, at the desired positions, orientations, and spacings, such that the lattice structure 212 (including the support members 206) may be implemented into the inner volume 105 as a unit. In some embodiments, the support members 206 may be connected to one another to form the lattice 212, e.g., the upper and lower side tips of the side-by-side X-shaped support members 206 may be connected to one another as shown in FIG. 9 and described below. In any of these embodiments, the lattice structures 212 may be easily placed into the shell’s inner volume 105 and may support themselves therein to simplify the manufacturing process. The core 200 may include one or multiple lattice structures 212. While the lattice structures 212 are shown as linked blocks implemented in the lower portion of the shell assembly 100 in FIG. 4, it is understood that the lattices 212 may be formed in any suitable shapes implemented in any areas of the shell’s inner volume 105, e.g., on the sides, in the corners, etc. In addition to the lattice structures 212, other support members 206 may be implemented individually within the same cooler assembly 10.

[0064] FIG. 9 shows a cross sectional view of the shell assembly 100 showing the support members 206 connected to one another in series to form corresponding lattices 212 extending generally continually across the inner volume 105 of the shell assembly 100. As shown, a first lattice 212 may be implemented generally vertically within the left side of the assembly 10, a second lattice 212 may be implemented generally horizontally within the bottom of the assembly 10, and a third lattice 212 may be implemented vertically within the right side of the assembly 10. The bottom of the first lattice 212 may be connected to the top left end of the second lattice 212, and the bottom of the third lattice 212 also may be connected to the top right of the second lattice 212. In other embodiments, the first, second and / or third lattices 212 may not be connected to one another.

[0065] FIG. 9 also shows a vacuum port 116 to which a vacuum pump or other vacuum apparatus may be attached to remove the fluid(s) (e.g., air) from within the shell’s inner volume 105 to provide a vacuum insulation therein. In addition, a measurement port 118 (e.g., a mercury gauge port) also may be provided to measure the vacuum pressure within the inner volume 105. The vacuum port 116 and / or the measurement port 118 may preferably reside within accessible recesses or other protected areas within the outer protective shell and extend into the inner volume 105.

[0066] FIG. 10 shows a cross sectional view of the core assembly 200 showing support members 206 and lattices 212 throughout the inner volume 105 and including tab or nail brace inserts 213 configured with the support members 206. As shown, a first end of each nail brace insert 213 may be positioned to abut against the inner sidewall surface 110 of the outer shell 100 and a second end opposite the first end may be positioned to abut against the outer shell’s inner sidewall 114 so that the nail brace insert 213 may pass through the center of corresponding X-shaped support member 206. FIG. 10 also shows the upper sealing members 106 that may be configured to extend across the top surfaces of the outer and inner shells 102, 104 and that may be bonded thereto using cold welding, crimping, and / or other suitable bonding techniques. Once sealed, the shell’s inner volume 105 and the support core 200 therewithin may be placed under vacuum pressure as described in other sections.

[0067] FIG. 11 shows the support members 206 and lattices 212 implemented as bracing rails or cellular beams 214 including foot plates 216 on opposite sides connected to one another in the middle by a middle beam 218. The cellular beams 214 may be designed to be placed into the shell’s inner volume 105 such that the outer surface of the first foot plate 216 may abut against the inner surface 110 of the outer shell 102 and the outer surface of the second foot plate 216 may abut against the inner surface 114 of the inner shell 104 and with the middle beam 218 extending therebetween to provide support to the inner surfaces 110, 114 during the vacuum process.

[0068] In some embodiments, the cellular beams 214 may be positioned within the core 200 vertically (e.g., within the sides of the core 200), horizontally (e.g., within the sides and / or the bottom of the core 200), diagonally (e.g., within the sides and / or the bottom of the core 200), at any desired orientation, and / or in any combinations thereof.

[0069] In some embodiments, the cellular beams 214, e.g., the middle beam 218, may include holes 220 passing from one side to the other opposite side to allow fluid (e.g., air) to pass from one side of the cellular beam 214 to the other side. In this way, when the inner core 200 is placed under vacuum, the vacuum may be balanced on both sides of the beams 214 within the core 200. In some embodiments, the holes 220 may be circular, polygonal (e.g., hexagonal) and / or any suitable shapes.

[0070] In some embodiments, the cellular beams 214 may be extruded using aluminum and / or other suitable metals and / or rigid thermoplastics such as polyvinyl chloride (uPVC), ABS, polycarbonate (PC), high-impact polystyrene (HIPS), polyethylene (PE / HDPE), polypropylene (PP), and / or engineering plastics such as nylon.

[0071] In some embodiments, as shown in the lower image of FIG. 11, the cellular beams 214 may be bent or otherwise formed (e.g., into curved shapes) to fit within the shell’s inner volume 105 and to support the inner cores 200 of the same curved shape. For example, as shown in FIG. 12, a plurality of curved cellular beams 214 may be aligned within one another and bent to form a three-dimensional U-shaped form (or other desired form). In this way, the cellular beams 214 may be positioned within a shell’s inner volume 105 of the same form to support the shell 200 during the vacuum process. In some embodiments, the plurality of cellular beams 214 may be coupled together using one or more connection plates 222 that may hold the plurality of curved cellular beams 214 together as necessary for the placement into the inner volume 105 and / or for the securing of the beams 214 together and / or therein. It is understood that the plurality of cellular beams 214 also may be formed into any other shapes as desired.

[0072] FIG. 13 shows support members 206 formed into a lattice 212 formed as a suspension bridge. In some embodiments, the suspension bridge may include a first series of support members 206 on a first side (e.g., zig zag or knee-knocker elements on the left side), a second series of support members 206 on a second side (e.g., nail brace inserts 213 in parallel along the top side), a third series of support members 206 on a third side (e.g., X-shaped support members 206 on the right side also as shown in FIG. 14), and a fourth series of support members 206 on fourth side (e.g., on the bottom). It is understood that the types of support members 206 described above are meant for demonstration and that other types of support members 206 may be used on any of the sides.

[0073] FIG. 15 shows a lid assembly 300 that may include a similar architecture as the cooler body portion, e.g., an upper shell and a lower shell configured to include an inner volume therebetween that may be placed under vacuum pressure, and a support core therein. The lid assembly 300 is preferably designed to thermally seal the cooler’s inner compartment 12 when placed thereon.

[0074] In some embodiments, as shown in FIG. 15, the lid 300 may include an upper shell wall 302 and a lower shell wall 304 (and including sides) that when combined form an inner volume 306 that may be under vacuum pressure as described in relation to the inner volume 105 as described above. In some embodiments, the inner volume 306 of the lid 300 may include one or more support members 206 and / or one or more support lattices 212 extending across the inner volume 306 to support the upper and lower shell walls 302, 304 as described above in relation to the outer shell 102 and the inner shell 104.

[0075] In some embodiments, the support members 206 and / or the lattices 212 may be implemented and held in place within the inner volumes 105, 306 (e.g., against the inner sidewalls 110, 114 of the inner and outer shells 102, 104) using adhesive, pressure fit, size fitting, spot welding, gravity, and / or other attachment mechanisms to hold the members 206 in place during the manufacturing process.

[0076] In some embodiments, the core assembly 200 also may include a filling material 224 (see FIG. 5) that may be placed into the shell’s inner volume 105 to fill in the inner volume 105 around and in-between the support members 206 and / or the lattice structures 212. As such, it is preferable that the support members 206 and / or the lattice structures 212 be formed and configured within the inner volume 105 prior to placement of the filling materials 224 thereinto. For example, the filling material 224 may be poured into and / or otherwise inserted into the inner volume 105 after the support members 206 and / or lattices 212 have been configured as described herein. In this way, the filling material 224 may fill in any gaps or spaces within the inner volume 105 not occupied by the support members 206 and / or the lattices 212.

[0077] In some embodiments, the filling material 224 preferably includes a material with low thermal conductivity. In some embodiments, the filling material 224 preferably includes a material with low density.

[0078] In some embodiments, the filling material 224 may include an aerogel comprising silica (a silica aerogel), comprising polymers (a polymer-based aerogel), and / or other types of aerogels. Other suitable materials also may be used.

[0079] In some embodiments, the sealed shell assembly 100 (with the core assembly 200 configured therein), may include a vacuum port, e.g., in the bottom of the shell 100 (see FIG. 6) to enable connection of a vacuum pump (or similar vacuum apparatus) to remove the fluids (e.g., the air) from within the shell’s inner volume 105 to achieve an absolute (or near) vacuum therein. The shell assembly 100 also may include a measurement port (e.g., a mercury gauge port) to measure the vacuum pressure within.

[0080] In some embodiments, as shown in FIG. 15, the lid 300 may be inserted into a cavity or recess 308 within an outer protective shell 310. The protective shell 310 may comprise polypropylene or other suitable materials to protect the lid 300. The protective shell may be rotomolded or otherwise formed.

[0081] In some embodiments, the shell assembly 100 (with the core assembly 200 configured therein), also may be placed within a protective shell and sealed therein.

[0082] In some embodiments, the lid’s protective shell may be designed to register with the shell’s protective shell to provide an airtight thermal seal between the two when the lid 300 is closed.

[0083] It is understood that any details and / or aspects of any embodiments of the cooler assembly 10 described herein may be combined with any details and / or aspects of any other embodiments of the cooler assembly 10 in any way to form additional embodiment(s) of the cooler assembly 10 all of which are within the scope of the cooler assembly 10.

[0084] Where a process is described herein, those of ordinary skill in the art will appreciate that the process may operate without any user intervention. In another embodiment, the process includes some human intervention (e.g., a step is performed by or with the assistance of a human).

[0085] As used herein, including in the claims, the phrase “at least some” means “one or more,” and includes the case of only one. Thus, e.g., the phrase “at least some ABCs” means “one or more ABCs” and includes the case of only one ABC.

[0086] As used herein, including in the claims, term “at least one” should be understood as meaning “one or more”, and therefore includes both embodiments that include one or multiple components. Furthermore, dependent claims that refer to independent claims that describe features with “at least one” have the same meaning, both when the feature is referred to as “the” and “the at least one”.

[0087] As used in this description, the term “portion” means some or all. So, for example, “A portion of X” may include some of “X” or all of “X”. In the context of a conversation, the term “portion” means some or all of the conversation.

[0088] As used herein, including in the claims, the phrase “using” means “using at least,” and is not exclusive. Thus, e.g., the phrase “using X” means “using at least X.” Unless specifically stated by use of the word “only”, the phrase “using X” does not mean “using only X.”

[0089] As used herein, including in the claims, the phrase “based on” means “based in part on” or “based, at least in part, on,” and is not exclusive. Thus, e.g., the phrase “based on factor X” means “based in part on factor X” or “based, at least in part, on factor X.” Unless specifically stated by use of the word “only”, the phrase “based on X” does not mean “based only on X.”

[0090] In general, as used herein, including in the claims, unless the word “only” is specifically used in a phrase, it should not be read into that phrase.

[0091] As used herein, including in the claims, the phrase “distinct” means “at least partially distinct.” Unless specifically stated, distinct does not mean fully distinct. Thus, e.g., the phrase, “X is distinct from Y” means that “X is at least partially distinct from Y,” and does not mean that “X is fully distinct from Y.” Thus, as used herein, including in the claims, the phrase “X is distinct from Y” means that X differs from Y in at least some way.

[0092] It should be appreciated that the words “first,”“second,” and so on, in the description and claims, are used to distinguish or identify, and not to show a serial or numerical limitation. Similarly, letter labels (e.g., “(A)”, “(B)”, “(C)”, and so on, or “(a)”, “(b)”, and so on) and / or numbers (e.g., “(i)”, “(ii)”, and so on) are used to assist in readability and to help distinguish and / or identify, and are not intended to be otherwise limiting or to impose or imply any serial or numerical limitations or orderings. Similarly, words such as “particular,”“specific,”“certain,” and “given,” in the description and claims, if used, are to distinguish or identify, and are not intended to be otherwise limiting.

[0093] As used herein, including in the claims, the terms “multiple” and “plurality” mean “two or more,” and include the case of “two.” Thus, e.g., the phrase “multiple ABCs,” means “two or more ABCs,” and includes “two ABCs.” Similarly, e.g., the phrase “multiple PQRs,” means “two or more PQRs,” and includes “two PQRs.”

[0094] The present invention also covers the exact terms, features, values and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., "about 3" or “approximately 3” shall also cover exactly 3 or "substantially constant" shall also cover exactly constant).

[0095] As used herein, including in the claims, singular forms of terms are to be construed as also including the plural form and vice versa, unless the context indicates otherwise. Thus, it should be noted that as used herein, the singular forms “a,”“an,” and “the” include plural references unless the context clearly dictates otherwise.

[0096] Throughout the description and claims, the terms “comprise”, “including”, “having”, and “contain” and their variations should be understood as meaning “including but not limited to”, and are not intended to exclude other components unless specifically so stated.

[0097] It will be appreciated that variations to the embodiments of the invention can be made while still falling within the scope of the invention. Alternative features serving the same, equivalent or similar purpose can replace features disclosed in the specification, unless stated otherwise. Thus, unless stated otherwise, each feature disclosed represents one example of a generic series of equivalent or similar features.

[0098] The present invention also covers the exact terms, features, values, and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., "about 3" shall also cover exactly 3 or "substantially constant" shall also cover exactly constant).

[0099] Use of exemplary language, such as “for instance”, “such as”, “for example” (“e.g.,”) and the like, is merely intended to better illustrate the invention and does not indicate a limitation on the scope of the invention unless specifically so claimed.

[0100] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A cooler assembly comprising:a first shell wall aligned with a second shell wall forming a shell inner volume therebetween, the first shell wall including a first shell inner surface facing the shell inner volume and the second shell wall including a second shell inner surface facing the shell inner volume; andat least one support member configured within the shell inner volume and extending from the first shell inner surface to the second shell inner surface to provide support therebetween;wherein the shell inner volume is placed under vacuum pressure.

2. The cooler assembly of claim 1 wherein the at least one support member is configured to prevent deformation of the first shell wall and / or the second shell wall when the shell inner volume is placed under vacuum pressure.

3. The cooler assembly of claim 1 wherein the at least one support member includes a plurality of support members arranged in a matrix.

4. The cooler assembly of claim 3 wherein the matrix comprises at least one horizontal series of support members and at least one vertical series of support members.

5. The cooler assembly of claim 1 wherein the at least one support member includes two or more at least one support members coupled to one another to form a support lattice.

6. The cooler assembly of claim 1 wherein the at least one support member includes at least one X-shaped support member.

7. The cooler assembly of claim 6 wherein a top two tips of the at least one X-shaped support member abut against the first shell inner surface and a bottom two tips of the X-shaped support member abut against the second shell inner surface.

8. The cooler assembly of claim 1 wherein the at least one support member includes a cellular beam.

9. The cooler assembly of claim 8 wherein the cellular beam includes at least one hole passing through the cellular beam.

10. The cooler assembly of claim 1 wherein the first shell inner surface and second shell inner surface are opposing one another.

11. The cooler assembly of claim 1 further comprising a valve leading into the shell inner volume for placing the shell inner volume under vacuum pressure.

12. A method of making a cooler assembly including an inner core under vacuum pressure, comprising:aligning a first shell wall with a second shell wall to form a shell inner volume therebetween, the first shell wall including a first shell inner surface facing the shell inner volume and the second shell wall including a second shell inner surface facing the shell inner volume;configuring at least one support member within the shell inner volume and extending from the first shell inner surface to the second shell inner surface to provide support therebetween; andplacing the shell inner volume under vacuum pressure.

13. The method of claim 12 wherein the configuring the at least one support member within the inner volume includes configuring a plurality of support members in a matrix.

14. The method of claim 13 wherein the matrix comprises at least one horizontal series of support members and at least one vertical series of support members.

15. The method of claim 12 wherein the at least one support member includes two or more at least one support members coupled to one another to form a support lattice.

16. The method of claim 12 wherein the at least one support member includes at least one X-shaped support member.

17. The method of claim 16 wherein a top two tips of the at least one X-shaped support member are configured to abut against the first shell inner surface and a bottom two tips of the X-shaped support member are configured to abut against the second shell inner surface.

18. The method of claim 12 wherein the at least one support member includes a cellular beam.

19. The method of claim 12 wherein the first shell inner surface and second shell inner surface are aligned to be opposing one another.

20. The method of claim 12 further comprising using a valve leading into the shell inner volume to place the shell inner volume under vacuum pressure.

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