BACKGROUND AND PRIOR ART Various types of cooler type containers have been proposed over the years from simple designs to complex devices. Many devices have been proposed that are simple in design and use. See for example, U. S. Patents: Des. 135,896 to Clerc. Des.

180,928 to Bliss; Des. 199,826 to Reichow; Des. 289,817 to Morrissette; Des.

364,073 to Langley; Des. 382, 885 to Deiner et al. ; Des. 451,767 to Kolpin; 3,654, 773 to White; 3, 882, 628 to Stouder; 4,403, 483 to Lisalda; 4,546, 900 to Lackey ; 4,724, 682 to Flum et al.; 5,397, 010 to Gibot; 6,151, 910 to Hazen; 6,415, 623 to Jennings et al., which generally show containers such as buckets and cylinders with or without insulated liners placed inside the containers. However, these simple devices are only temporary storage devices for picnic type applications, and the like. These devices generally solely rely on single layer type container walls with or without insulated liners, and are not able of keeping content items cold over long periods of time.

Other simple devices have been proposed that use some type of basic refrigerant. See U. S. Patents Des. 313, 026 to Evans; 4,054, 037 to Yoder; and 4,821, 914 to Owen et al. However, these devices are limited to a one time use of keeping contents of a container such as a single soda can cold, and are not intended for continuous use for cold storing of other items unless the refrigerant is recharged overtime.

More elaborate cooler devices with motors have been proposed that can allow for longer term storage of items. See for example, U. S. Patents: 4,711, 099 to Polan et al. and 5,181, 393 to Lott. However, the Polan'099 device is also limited to keeping only a single container such as a single can of soda cold, and has no lids or covers for cold storage of plural items safely overtime. The Lott'393 patent describes a "Refrigerated Waste Container with Germicidal Lamp"that is an elaborate and expensive to construct trash can that is used to"kill microorganisms in the waste" with a"germicidal lamp"and has no capability of easily storing multiple items as a cooler. Still furthermore, both Polan and Lott would both be difficult to construct multiple versions in an easy and cost effective manner.

Normal freezers and refrigerators can be used for long term beverage and food storage but generally require defrost cycles every few hours in order to keep frost from accumulating on these devices. These traditional freezer and refrigerator devices usually require a defrost heater, a defrost timer, and a defrost terminator, as well as large compressors to achieve sufficient cooling temperatures. Furthermore, these prior art freezers and refrigerators often require condensation drains that require extra expense to be used. These freezers and refrigerators are often quite bulky and restrict the interior storage space because of the need to house all of the defrosting components. Thus, traditional freezers and refrigerators are not practical to be portable, versatile coolers that can be used in various applications such as with automobiles, boats, and the like.

Furthermore, none of the other devices referenced above has the versatility and capability to be able to be used in pleasure crafts from small craft boats to sail boats through yachts. Additionally, none of the above devices has the versatility and capability to be able to be used in vehicles such as vans, SUVs (sport utility vehicles), station wagons, motor homes, and the like, and cannot use vehicle batteries as the source of power. None of these prior art devices are also aesthetic and stylish and practical for regular reusable cold storage of food and beverage items.

Thus, the need exists for solutions to the above problems with the prior art.

SUMMARY OF THE INVENTION A first objective of the present invention is to provide methods of making reusable and portable cooler containers for storing food and beverage items that can be both portable, and inexpensive to build and use, as well not require traditional defrost components and/or condensation drains used with traditional refrigerators and freezers.

A second objective of the present invention is to provide methods of making reusable and portable cooler containers for storing food and beverage items that can be created from five gallon type paint buckets and are easy and inexpensive to assemble, to use and to operate.

A third objective of the present invention is to provide cooler devices that can be salable, waterproof, and reusable overtime.

A fourth objective of the present invention is to provide cooler devices that are portable and versatile to be used on pleasure crafts from small boats to sailboats through yachts.

A fifth objective of the present invention is to provide cooler devices that are portable and versatile to be used in motor vehicles that can include automobiles, vans, SUVs (sport utility vehicles), trucks, motor homes, and the like, that can use cigarette lighter adapters for connecting to the vehicle battery as a power supply.

A sixth objective of the present invention is to provide cooler devices and methods of making cooler devices that are both aesthetic and stylish and practical for as use a reusable coolers for food and beverage items.

A preferred method of making a portable cooler and a preferred cooler device that does not require any defrost components or drains, can include the steps of : applying a first layer of metal tape about a plastic bucket, wrapping the bucket with first tape layer with coiled refrigerant tubing, applying a second layer of metal tape about the coiled refrigerant tubing, applying insulation tape about the second layer of metal tape, placing foam about the insulation tape to form an evaporator container, housing the evaporator container in a metal container, connecting the refrigerant tubing to a condenser and compressor assembly and power supply to form a cooler that does not require defrost components or drains, and accessing the plastic bucket of the cooler through a removable portal lid covering a top of the cooler.

A five gallon plastic paint can type bucket can be used as the plastic bucket.

Silver metal type duct tape can be used as the first and the second metal tape layers, and foam tape can be used as the insulation tape. Approximately'/4 inch diameter copper tubing in a spiral configuration can be used as the coiled refrigerant tubing.

The outer foam layer can be poured from a liquid foam source. Alternatively, foam sections can be used and attached to the refrigerant tubing sides.

The power supply can be 12 volt battery inside the metal container. Also, the power supply can be an electrical connection to an exterior 120 volt power source.

Additionally, the power supply can be an electrical connection to an exterior 220 volt power source. The power supply can also be an electrical connection to an exterior 12 volt battery.

The exterior surface of the metal container can be diamonized aluminum. The exterior metal surface can be powder coated or painted various colors and/or designs.

The lid cover to the cooler for allowing top loading and access to the cooler can be a pop-off disc cover, which is removed by a hinged loop tab type handle.

Versions of the cooler can be rectangular, square, and cylindrical with or without wheels, and include coolers of various dimensions and weights. A handheld version can include dimensions of less than approximately 15 inches wide by approximately 9 inches tall by approximately 31 inches long, a weight of less than approximately 30 pounds, and a swivel type handle attached to the container housing for allowing the cooler to be hand carried with ease.

Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES Fig. 1A is a perspective view of a first preferred embodiment of the cooler invention.

Fig. 1B is a side view of the cooler of Fig. 1A along arrow 1B.

Fig. 1C is a top view of the cooler of Fig. 1B along arrow 1C.

Fig. 1D is a bottom view of the cooler of Fig. 1B along arrow 1D.

Figures 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, 2I, 2J, 2K, 2L, 2M, 2N, 20,2P, 2Q, 2R show the various assembly steps for constructing and making the cooler of Figures lA-1C.

Fig. 3 is a partial cross-sectional view of cooler of Fig. 2Q along arrows 3-3.

Fig. 4 shows an interior view of the assembled cooler of Fig. 2Q.

Fig. 5 is a perspective view of a second preferred embodiment of the cooler.

Fig. 6 is a perspective view of a third preferred embodiment of the cooler.

Fig. 7 is a perspective view of a fourth preferred embodiment of the cooler.

Fig. 8 shows the coolers of the preceding embodiments for use in automobiles.

Fig. 9 shows the coolers of the preceding embodiments for use in a motor home.

Fig. 10 shows the coolers of the preceding embodiments for use in a boat.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.

Fig. 1A is a perspective view of a first preferred embodiment of the cooler 1 invention. Fig. 1B is a side view of the cooler 1 of Fig. 1A along arrow 1B. Fig. 1C is a top view of the cooler 1 of Fig. 1B along arrow 1C. Fig. 1D is a bottom view of the cooler 1 of Fig. 1B along arrow 1D.

Referring to Figures lA-1D, the cooler 1 can be approximately 31 inches tall by approximately 15 inches wide, and can include an upright rectangular configuration having a square faced top 10, square faced bottom 20 and rectangular side faces 30,40, 50 and 60. Top 10 can include a lid portion 12 formed from a disc shaped plastic type material that pops up to completely separate from the cooler 1 by pulling upward on a foldable loop handle 14. Bottom 20 can include four wheels 22, 24,26, 28 attached thereto. The side faces 30,40, 50, 60 can be formed from an aluminum diamond patterned outer skin layer, and include vents 35,55, and controls 70 for switching between refrigerator and freezer operations, and temperature set controls 80 for adjusting operating temperatures of the cooler 1.

METHOD OF MAKING THE COOLER Referring to Fig. 2A, the invention can initially start with a plastic 5-gallon polyethylene container, such as used as a paint container, with an approximate width of approximately 15 1/2 high and approximately 12 inches wide. First, the container 100 can be wrapped with silver metal type tape 110 such as the tape used in wrapping air conditioning ductwork to substantially and completely cover the bucket container 100 with the tape as shown in Fig. 2B. Next, approximately 1/4 inch copper refrigerant tubing 120 can be wrapped over tape 110 and this tubing 120 can be spaced approximatelyl inch apart between the rows as shown in Fig. 2C. When this is done, the copper tubing 120 can be wrapped with another layer of silver tape 130 (which is identical to the tape 110 previously used) as shown in Fig. 2D.

When the copper tubing 120 is finished being wrapped around the cooler, and before placing the second layer of metal tape 130 on the copper tubing 120, a single section of tubing 127 can be placed in between rows of tubing adjacent to a midportion of the container 125 for the thermostat 85 to slide inside a open end of the 5 inch piece of tubing. This copper tubing can have one end closed, and the other end can stay uncovered to accept the thermostat capillary tube. Once this short section of copper tubing 127 is in place, and this copper tube section 127 can be positioned about a midportion of the cooler 1 also. This copper section 127 will be to house the thermometer sensor bulb 85 for reading the cooler/freezer temperatures to be later described. When the tubing 130 has been wrapped by tape 130, end portions 121,123 of the copper tubing 130 can be left in order to be bent over pointed towards the bottom of the container 100. The ends 121,1223 can be a beginning, and an end of the copper tubing showing up at the bottom of the cooler case. This tubing ends 121, 123 can be pushed through the bottom on the coolers metal outer case to be connected to the compressor which is later described.

Referring to Fig. 2E, the silver tape 130 can be covered with approximately 1/4 inch foam sealing tape 140 in order to keep moisture formation and leakage down to a minimal and to prevent sweating from the exterior of the container surface 100 outward.

The wrapped bucket formed from Figures 1A-2E forms an evaporator type container EC.

Referring to Figures 2F-2G, box frame 200 that can be formed from wood, and the like, can be used for housing the evaporator container EC. The box frame can have an upper compartment 210 and a lower compartment 220 with a ledge-shelf 230 there between. The evaporator container EC can be placed through an upper opening of a box frame 200 and supported by the ledge-shelf 230 with the copper tube ends 121,123 protruding downwardly through the ledge-shelf 230. Spacers 235 can be used on the ledge-shelf 230 to raise the container EC approximately 2 and ! 4 inches up if poured foam is being used.

Referring to Fig. 2H, interior spacers 240I such as slats can be placed about the EC container to enter the EC container inside the upper compartment 210. Exterior spacers 240E can be placed inside and adjacent to outer walls 212 of upper compartment 210 to form a continuous space therebetween with 245 about evaporator container EC.

Referring to Figures 2I-2J, a liquid foam 251 from a liquid foam source 250 such as polyethylene, closed cell foam, and/or open cell foam, can be poured into the space 245 inside upper compartment 210 about evaporator container EC to form a continuous layer 255. The foam layer 255 can seal the airspace 245 between the evaporator container EC and outer walls 212 of the upper compartment 210. After the foam layer 255 has cured overtime, for example, after approximately 24 hours, excess foam 257 that extends out of the space 245 above compartment 210 can then be trimmed and removed by a knife, and the like.

Alternative to pouring foam, the invention assembly can use foam inserts, such as two foam inserts that can be inserted around the evaporator container EC until they touch each other to form a foam wrapped evaporator container EC. Next, the foam wrapped evaporator container can be carefully inserted inside the upper compartment 210 case making sure that it is not damaged or crushed during the process. As the foam wrapped evaporator container EC is being lowered down the foam wrapped container should seat all the way down against the inner shelf-ledge 230. After the evaporator is fitting properly, slowly once again, remove the foam and the evaporator container back out of the bucket and set is aside.

Referring to Figures 2K-2L, the top 10 can be installed by pressing the top over the opening 219 of the upper compartment 210 so that lip edge side 18 rests against upper edge 218 of the upper compartment. The top 10 can be sized for a tight fit, and can be removable as needed for maintenance and cleaning of the evaporator container EC. The top 10 can be installed by being tapped into place with a soft rubber mallet or hammer until the lip side 18 abuts against upper edge 218.

When the evaporator container EC is properly seated, the foam layer 255 and the evaporator container EC will be flush with the outside of a box 200 which can be wrapped within a metal layer 260 such as diamond aluminum plating, and the like.

Alternatively, a plane metal layer can be used that is smooth painted or powder coated with various choices of colors, as desired.

Although the invention describes the box 200 being composed of separate spaced compartments 210,220 that are later wrapped with a metal layer 260, the invention can instead use a single metal box without any separate wrapped layers.

Referring to Fig. 20, hole openings 272,274, 276, and 278 can be cut through outer metal layer 260 of the metal wrapped boxed container MBC, at different locations so that the refrigerator/freezer switch, thermostat, compressor access drawer, and vents, respectively can be later mounted thereon. Referring to Fig. 2P, wheels 22, 24,26, 28 can be installed onto the bottom 20 of the MBC container to allow the cooler to be easily moveable over floor surfaces.

Referring to Figures 2P, 2Q and 2R, refrigerator/freezer switch 70, thermostat 80 and vent cover 55 can be installed onto side openings 272,274, 278 of MBC container.

Fig. 3 is a partial cross-sectional view of cooler of Fig. 2Q along arrows 3-3.

Fig. 3 shows the relationship of the inner bucket 100 (Fig. 2A), to first tape layer 110 (Fig. 2B), wrapped tubing 120 (Fig. 2C), second metal tape layer 130 (Fig. 2D), insulation tape layer 140 (Fig. 2E), foam outer layer 255 (Fig. 2I/2J), outer box walls 210/212 (Fig. 2H) and exterior metal layer 260 (Fig. 2N).

Referring to Figures 2Q, 2R and 4, another opening 265 that can have dimensions of up to approximately 15 inches by approximately 15 inches can be cut through the rear of the lower half of the MBC container to allow for a drawer-tray 310 to be inserted over the floor 222 of lower inside compartment 220. Drawer-tray 310 can be used to support a removable 12-volt type compressor 310 or a 120 volt compressor as well as a 240 volt 50Hz compressor, and the like, thereon, that can be slid into the side opening 265 of MBC container. The compressor drawer-tray 310 can be easily pulled out of the bottom compartment 220 for installation and servicing as needed. Pins 315, can be used to lock the drawer-tray in place after installation.

Referring to Fig. 4, adjacent to compressor drawer-tray 310 can be another drawer-tray 330 that can support a 12-volt battery source 340. On the right, can be another drawer-tray 350 that can support a fan 370 and condenser 380. Alternatively, one approximately 10 X 10 drawer-tray such as one formed from aluminum can be used to support both the compressor 320 and condenser/fan assembly 360-370.

Additional hole-openings can be cut into the metal layer 260 of the MBC container for also allowing access to these components.

Referring to Fig. 4, the temperature setting control 80 can be connected to the thermostat 85 inside of the copper tubing section 127 that was previously described.

Refrigerator/freezer control 70 can be a three-way switch 72 that can switch between a refrigeration-on position, an off position, and a freezer-on position. Temperature setting screws 74 and 76 can control temperature settings for the refrigerator and freezer, respectively, and can each be factory preset to selected temperatures, and further modified by adjusting the screws as needed. Additionally, or alternatively, a single cold control with both refrigeration and freezer capabilities can be used instead of a switch assembly and two individual thermostats. The controls can also be adjusted as needed by the users.

As shown in Fig. 4, the compressor 320 can be positioned and mounted behind the condenser/fan assembly 360/370, the latter of which can be located next to a right discharge grill vent 55, while the battery/power source 340, can be mounted adjacent to a left discharge grill vent 65. A strap 342 can wrap about the battery power source 340 to the interior walls 224 of the lower compartment 220. Tubing line ends 121, 123 from the EC container can be designated as a LIQUID LINE and a SUCTION LINE. so, that refrigerant can move from the bottom of the EC container to the top of the cooler for greater efficiently of the evaporator temperatures. The compressor 320 can be pre-charged with a proper amount of refrigerant as needed to be in the compressor 320. The EC container can have a pre-charge also if this is a build up kit that is being put together. If this is a building process of the cooler, then the refrigerant lines will still be void of gas, and one will have to vacuum down the system and charge the lines with the correct charge when you have finished the solder connections. Quick disconnects to the system lines can come from the factory, and will be totally sealed, and the refrigerant gases will stay inside each half of the system until the fittings have been completely connected together and bottomed out; then the gas will flow from the compressor 320 to the EC container. The condenser 360/370 assembly and battery power source 340 can be connected to the system together to complete the cooler assembly CA.

While the invention has been described as being powered by a 12 volt power supply, 340 Figures 4 and 4A, the invention can use other power supplies such as an approximately 120 volt or 220 volt alternating current (AC) power supply 340C that connects to the cooler assembly CA by a conventional plug 343. Alternatively, the cooler assembly CA can be powered by a cigarette lighter adapter 340B which plugs into the power supply 345 such as a 12 volt DC (direct current) power supply found in vehicles, boats, and the like. The novel invention can be powered by 110 or 220 volt 60 HZ or 50 Hz power supply or by 12volt DC power supplies.

The five gallon plastic bucket inside of the assembled cooler AC, can easily store and cool or chill beverage items such as but not limited to up to approximately 30 (thirty) 12 (twelve) ounce cans of beverages such as soda and beer. The bucket can further store and cool or chill food items such as but not limited to sandwiches, fruits, vegetables, and the like. The cooler can be adjusted to temperature ranges from approximately 38 degrees F to approximately 0 degrees F as needed with the temperature setting controls and when being operated as a refrigerator or freezer.

Fig. 5 is a perspective view of a second preferred embodiment of the cooler 400 which shows a rectangular top and bottom configuration as a variation of the cooler 1 embodiment previously described.

Fig. 6 is a perspective view of a third preferred embodiment of the cooler 500 which shows a cylindrical type configuration as a variation of the cooler embodiments previously described.

Fig. 7 is a perspective view of a fourth preferred embodiment of the cooler 600 with a small portable unit that can have a main compartment 610 having dimensions of no more than approximately 15 inches by approximately 9 inches tall and wide by approximately 31 inches long and weight less than approximately 30 pounds. A swivel ended handle 660 can be used to support the main compartment 610.

Alternatively, a shoulder strap can be used with or without the handle 660. Inside the main compartment can be condenser/fan 650, battery power supply 640 and compressor 630 similar to those previously described. The EC container P can be approximately ! 4 the size of the EC container of the previous embodiments, where approximately 1/2 of a five gallon plastic bucket is used as the bases for the portable EC container P.

Fig. 8 shows the coolers 1, 600 of the preceding embodiments for use in automobiles 700 such as but not limited to vans, station wagons, SUV (sport utility vehicles), and the like.

Fig. 9 shows the coolers 1, 600 of the preceding embodiments for use in a motor home 800.

Fig. 10 shows the coolers 1,600 of the preceding embodiments for use in a boat such as a yacht, sailboat, small craft, and up to a large cruise ship and the like, where the novel cooler inventions can be used in the staterooms on cruise lines, and the like, because of its compact size.

Additionally, the cooler/freezer can also be used in commercial applications such as in commercial restaurant accounts, and many other commercial and residential home uses as needed.

The invention can also be incorporated into a kit form for assembly.

Although the preferred embodiments describe storing food and beverage type items in the coolers, the invention can be used to store other items such as but not limited to biological tissues, drugs, any other small items requiring cold storage, and the like, and used in a variety of applications such as but not limited to medical applications, and the like.

While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.