WO2018170337A2

WO2018170337A2 - Drop-stitch for an inflatable device

Info

Publication number: WO2018170337A2
Application number: PCT/US2018/022757
Authority: WO
Inventors: Todd Bradley
Original assignee: Swell Industries Llc
Priority date: 2017-03-17
Filing date: 2018-03-15
Publication date: 2018-09-20
Also published as: WO2018170337A3

Abstract

Methods and systems are provided for an inflatable device. In one example, an inflatable device comprises a drop-stitch having a layer, such as a thermally insulating material located therein, the layer separating the drop-stitch into first and second air cells, and where the thermally insulating material is configured to selectively or at least partially seal the first air cell from the second air cell.

Description

DROP-STITCH FOR AN INFLATABLE DEVICE

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application No. 62/473,294, entitled "DROP-STITCH FOR AN INFLATABLE DEVICE", and filed on March 17, 2017. The entire contents of the above-listed application are hereby incorporated by reference for all purposes.

FIELD

[0002] The present description relates generally to inflatable devices. BACKGROUND/SUMMARY

[0003] The inventors herein have recognized that lightweight inflatable coolers can present various technical challenges in terms of thermal insulation, portability, rigidity, ease of use, etc. One example approach for a cooler includes an inflatable cooler comprising: first and second air cells having a material layer separating said first and second air cells, the layer configured to selectively or partially seal the first air cell from the second air cell.

[0004] It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIGS. 1A and IB show perspective views of an inflatable cooler in an expanded condition.

[0006] FIGS. 1C and ID show perspective views of the inflatable cooler in a condensed condition.

[0007] FIG. 2A shows a cross-section of a drop-stitch fabric.

[0008] FIG. 2B shows an embodiment of the drop-stitch fabric having a single chamber partially separated into first and second air cells via an interior layer.

[0009] FIG. 3 A shows an example of air flow through the first and second air cells when the valve of the inflatable device is not in use. [0010] FIG. 3B shows an example of air flow through the first and second cells when the valve of the inflatable device is actuated.

[0011] FIG. 4A shows an example of air flow through the first and second cells without drop stitch when the valve of the inflatable device is not in use.

[0012] FIG. 4B shows an example of air flow through the first and second cells without drop stitch when the valve of the inflatable device is actuated.

[0013] FIGS. 1-4B are shown approximately to scale.

[0014] FIG. 5A shows an aerial view of the inflatable cooler in un-zipped configuration.

[0015] FIG. 5B shows a perspective view of the inflatable cooler in un-zipped configuration.

[0016] FIG. 6A shows an example embodiment of a cross-sectional view of panels of the inflatable cooler

[0017] FIG. 6B shows another example embodiment of a cross-sectional view of panels of the inflatable cooler.

[0018] FIG. 7 is a detailed view of a dual-layer panel.

[0019] FIG. 8 is a detailed view of another dual-layer panel.

DETAILED DESCRIPTION

[0020] The following description relates to systems and methods for an inflatable device comprising sections with drop-stitching as well as with no drop-stitching and no foam (although foam may be used, if desired). As used herein, drop-stitching includes first and second planar fabric layers coupled together via sets of drop-stitched lines therebetween. An inflatable device that is non drop-stitching excludes the use of drop-stitched lines between first and second planar fabric layers and may further exclude interior foam, at least in some sections and possibly every panel section.

[0021] An example of an inflatable cooler is shown in FIGS. 1A-1D. However, it will be appreciated by those skilled in the art that the example approaches described herein may be utilized in a plurality of inflatable devices. For example, the inflatable devices may include a sleeping pad, a pillow, a balloon, a stand-up paddle board, a floatation device, and/or a seating accessory or other devices. In one example, a first cell and a second cell are coupled together in a single chamber. An interior layer between the first and second cells, which may be one of the fabric layers of the drop-stitch of the first and second cells, or an additional layer between outer surfaces of one fabric of the first and second drop-stitch cells, is elongated with respect to the other materials and separates the first and second cells from one another. An outer shell may enclose both the first and second drop-stitch cells, including the interior layer between the cells, the outer shell being able to hold pressure in the cells. The elongated interior layer may have at least one free end at one end, the free end only partially sealing, but not air-tightly sealing the cells from one another via, for example, engagement with an inner surface of the outer shell.

[0022] An example embodiment of drop-stitching material is shown in FIG. 2A.

[0023] In one example, the interior layer is a thermally insulating material. An example of a thermally insulating material separating the first and second air cells is shown in FIG. 2B. The thermally insulating material at least partially separates the first and second air cells via seals or partial seals at free ends slidingly engaging or resting against an inside wall of an outer layer enclosing the first and second cells, as shown in FIGS. 3A and 3B. While the figures show free ends at both ends, only one end may have the elongated flaps. In one example, the thermally insulating material divides and fluidly separates the chamber into two separate air cells when the valve is not being actuated, but not so tightly as to form an airtight seal. In this way, the chamber can still be deflated via a valve in only one of the air cells. Furthermore, the thermally insulating material fluidly couples the two air cells of the chamber when the valve is being actuated, such as during inflation.

[0024] FIGS. 1-5B show example configurations with relative positioning of the various components. If shown directly contacting each other, or directly coupled, then such elements may be referred to as directly contacting or directly coupled, respectively, at least in one example. Similarly, elements shown contiguous or adjacent to one another may be contiguous or adjacent to each other, respectively, at least in one example. As an example, components laying in face-sharing contact with each other may be referred to as in face- sharing contact. As another example, elements positioned apart from each other with only a space there-between and no other components may be referred to as such, in at least one example. As yet another example, elements shown above/below one another, at opposite sides to one another, or to the left/right of one another may be referred to as such, relative to one another. Further, as shown in the figures, a topmost element or point of element may be referred to as a "top" of the component and a bottommost element or point of the element may be referred to as a "bottom" of the component, in at least one example. As used herein, top/bottom, upper/lower, above/below, may be relative to a vertical axis of the figures and used to describe positioning of elements of the figures relative to one another. As such, elements shown above other elements are positioned vertically above the other elements, in one example. As yet another example, shapes of the elements depicted within the figures may be referred to as having those shapes (e.g., such as being circular, straight, planar, curved, rounded, chamfered, angled, or the like). Further, elements shown intersecting one another may be referred to as intersecting elements or intersecting one another, in at least one example. Further still, an element shown within another element or shown outside of another element may be referred as such, in one example. It will be appreciated that one or more components referred to as being "substantially similar and/or identical" differ from one another according to manufacturing tolerances (e.g., within 1-5% deviation).

[0025] Turning now to FIGS. 1A-1D, an example inflatable cooler embodiment is provided. While this example may include drop-stitching, other examples have a similar structure but without any drop-stitching, or less drop-stitching.

[0026] The inflatable cooler 100 is one example of a variety of inflatable devices which may utilize the drop-stitching described herein. The inflatable cooler 100 includes a bottom portion 102 and a top portion 104. As shown, the top portion 104 includes a sealing mechanism 106 such as zipper or other suitable sealing mechanism. In one example, the sealing mechanism may be substantially watertight and/or airtight to reduce the likelihood of cooler leakage and improve insulation characteristics. However, numerous suitable sealing mechanisms have been contemplated. The sealing mechanism 106 enables a user to open or close the cooler to access or seal goods stored within such a food, beverages, and/or other items. The bottom portion 106 may include foot elements for resting the inflatable cooler 100 on a rough surface. Additionally, the foot elements provide the inflatable cooler 100 with a clearance for resting the inflatable cooler 100 on an uneven surface.

[0027] The inflatable cooler 100 also includes a plurality of sides. Each of the sides extends between the top portion 104 and the bottom portion 102. The sides and the top and bottom portions form boundaries of an interior storage compartment, such as the storage compartments described with regard to the other cooler embodiments. The sides can be conceptual divided into pairs and in the depicted embodiment the inflatable cooler 100 includes four sides. However, other inflatable cooler 100 layouts have been contemplated such as cooler having less or more than four sides, such as a cooler with three sides or six sides, for instance. The inflatable cooler 100 therefore includes a first pair of sides 108 with a first side 110 and a second side 112. The inflatable cooler 100 additionally includes a second pair of sides 114 with a third side 116 and a fourth side 118. The first side 110 and the second side 112 are positioned to oppose one another. Likewise, the third side 116 and the fourth side 118 are positioned to oppose one another. The inflatable cooler 100 has a trapezoidal shape in the depicted embodiment. However, other cooler shapes have been contemplated. In the depicted example, the first side 110 and the second side 112 have a similar boundary profile. That is to say the shape of the peripheral regions of the first and second sides of the cooler may be substantially identical. Likewise in the depicted example, the third side 116 and the fourth side 118 have a similar boundary profile. It will be appreciated that in some instances each side may include different accessories such as pockets, attachment features, valves, etc., and that sides with varying geometries have also been contemplated.

[0028] The inflatable cooler 100 may be set in an expanded or condensed configuration based on a user's predilection. In FIGS. 1A-1D the inflatable cooler 100 is shown in different configurations. Specifically, FIGS. 1A and IB shows the inflatable cooler 100 in an expanded configuration and FIGS. 1C and ID show the inflatable cooler 100 in a condensed configuration. As such, the cooler can be compacted to enable easy storage, transportation, etc., when user of the cooler for storage of contents is not desired. For instance, a user may want to store their cooler in a compact manner when not in use. As such, the cooler may be arranged in the condensed configuration during storage, transport, etc., and then arranged into the expanded configuration when use of an interior storage compartment is desired. For instance, a user may store the cooler in a compacted form in the trunk of a car until contents such as ice, food, beverages, etc., are procured by the user. The cooler may then be quickly inflated and the items may be placed inside an interior storage compartment. In this way, the cooler's configuration can be altered, thereby increasing the adaptability and convenience of the cooler. In other examples, the cooler may be commercially shipped in the condensed configuration to reduce shipping costs. Retailers can also store the coolers in a condensed configuration to reduce the amount of space needed for cooler storage. Furthermore, the inflatable cooler 100 configured for collapsibility may be particularly useful in any circumstance where space is at a premium such as small planes, boats, etc. Additionally or alternatively, other inflatable devices utilizing the drop-stitch fabric described in FIGS. 2 A and 2B may comprise similar condensing and expanding features provided by the inflatable cooler 100.

[0029] Now specifically referring to FIG. 1A, the inflatable cooler 100 includes an inflation valve 120 configured to enable inflation and deflation of an inflation chamber 122 included in the inflatable cooler 100. Thus, the inflation valve 120 may be configured to accept a pump, in one example. The inflation chamber 122 may include sections 124 positioned in different sides of the cooler. In such an example, the sections may have fluidic communication (i.e., air can flow between the sections) via a connection section 126. However, in other examples each section of the inflation chamber 122 may have an associated inflation valve or a first set of inflation chamber sections may be in fluidic communication with a first inflation valve and a second set of inflation chamber sections may be in fluidic communication with a second set of inflation chamber sections. In such an example, the sections of the inflation chambers may be included in adjacent sides, in one instance, or on opposing sides, in another instance.

[0030] In another example, the inflation chamber 122 may be included in the first pair of sides 108 and the second pair of sides 114. In yet another example, the inflation chamber 122 may only be included in the second pair of sides 114. In such an example, the first pair of sides may include foam or other forms of insulation material. Inflating the inflation chamber 122 may move the inflatable cooler 100 into the expanded configuration, shown in FIGS. 1A and IB. On the other hand, deflation of the inflation chamber 122 may move the inflatable cooler 100 into the condensed configuration, shown in FIGS. 1C and ID. In other examples, additional input from the user may be needed to urge the cooler into the different configurations such as extending/retracting straps, pushing/pulling the first pair of sides 108, etc.

[0031] The first pair of sides 108 includes a plurality of foldable sections 128 that enable the sides of the cooler to be arranged in the expanded configuration shown in FIG. 1 A and the different condensed configurations shown in FIGS. 1C and ID. Although only the foldable sections 128 on the third side 116 are depicted in FIG. 1A it will be appreciated that the fourth side 118 also has similar foldable sections 128. The foldable sections 128 extend toward one another, in the illustrated example. Additionally in the illustrated example, the foldable sections 128 extend in a vertical direction. However in other examples, the foldable sections may have alternate contours. When folded, the foldable sections 128 may crease to enable first side 110 and the second side 112 to be folded down toward the bottom portion 102.

[0032] Continuing with FIG. 1A, in the expanded configuration distal ends 130 of the first side 110 and the second side 112 of the inflatable cooler 100 are further away from the bottom portion 102 when compared to the distal ends 130 of the first side 110 and the second side 112 in the condensed configuration shown in FIGS. 1C and ID. FIG. 1 A also shows the inflatable cooler 100 with a handle 132 enabling a user to easily carry the cooler in the expanded configuration.

[0033] FIG. IB shows an angle 140 formed between the first side 110 and the bottom portion 102 of the inflatable cooler 100. It will be appreciated that the second side 112 may also form a similar angle with the bottom portion 102. As shown, the angle 140 is measured from lines 142 parallel to and/or extending through outer surfaces 144 of the first side 110 and the bottom portion 102. When the outer surfaces are curved, tangent lines may be used to measure the angle. The angle 140 quantifies an angular position between the first side 110 and the bottom portion 102. The angle 140 is substantially 90 degrees in the embodiment depicted in FIG. IB. In this orientation, the first side 110 and the second side 112 may be arranged in a vertical orientation, when the cooler is on a level surface. However, it will be appreciated that the inflatable cooler 100 may be configured such that the angle may be adjusted. The adjustment may be achieved by at least partially deflating the inflation chamber 122, shown in FIG. ID, and folding the sides of the cooler along the foldable sections 128. As such, users can place the cooler in a desired configuration. The angle 140 can range from 0-90 degrees, in one example. In other examples, the angle 140 may range from 0-80 degrees or from 15-75 degrees. However other angular ranges have been contemplated. The thickness of the sides and bottom portion as well as other design factors may affect the angular range. It will be appreciated that the second side 112 may be folded in a similar manner to the first side 110.

[0034] Additionally, in FIG. IB the foldable sections 128 extend between an intersection 146 between the bottom portion 102 and the second pair of sides 114 and an intersection 148 between the top portion 104 and the second pair of sides 114. The placement of the foldable sections in this way enables the compact configuration to be achieved.

[0035] FIG. 1C and ID show the inflatable cooler 100 in the condensed configuration. As shown, in FIG. 1C the first side 110 and the second side 112 are folded down towards the bottom portion 102. As described above, the foldability of the cooler enables the configuration adjustment. The foldable sections 128 are shown creased in FIGS. 1C and ID.

[0036] FIG. ID shows the angle 140 between the first side 110 and the bottom portion 102. It will be appreciated that the angle 140 is decreased when the cooler is placed in the condensed configuration from the expanded configuration. In the condensed configuration, the angle 140 may be 30 degrees, 15 degrees, 0 degrees, etc. The magnitude of the angle may depend on the thickness of the cooler sides as well as other factors. It will be appreciated that when the angle 140 is small, in the condensed configuration, a more compact cooler profile to be achieved to enable the inflatable cooler to be easily handled, transported, stored, etc.

[0037] Turning now FIG. 2A, it shows a cross section of a drop-stitch fabric 200, as the term is used herein. The drop-stitch fabric 200 may form at least a body of an inflatable device (e.g., inflatable device 100 of FIGS. 1A-1D). The drop-stitch fabric 200 may include a double-wall construction having a first surface 210 and a second surface 220. The first surface 210 may comprise a base cloth 212, an inner layer 214, and an outer layer 216, and the second surface 220 may comprise a base cloth 222, an inner layer 224, and an outer layer 226. It will be appreciated that drop-stitch fabric 200 may be used in the manufacturing of a plurality of inflatable devices. For example, the drop-stitch fabric may be used to produce inflatable coolers, inflatable sleeping pads, inflatable mattresses, inflatable pillows, balloons, inflatable floatation devices (e.g., boats, paddle boards, and/or safety devices), and inflatable housing devices (e.g., bouncy house).

[0038] Base cloths 212 and 222 may be tethered via drop stitches 204 to provide a double-wall material of a specified thickness when inflated to a desired pressure. A space 202 may be located between base cloths 212 and 222. As one example, each of base cloths 212 and 222 may be constructed from a polyester material. However, it will be appreciated that in other examples, alternative suitable materials may be used. Drop stitches 204 may also be constructed from a polyester material, although the weight of the drop stitch material may differ from the weight of the material of the base cloths.

[0039] In one example, the drop-stitch 200 is divided into first and second drop-stitch layers, wherein each of the first and second drop-stitch layers each comprise an individual drop-stitch 200. Said another way, a first drop-stitch layer may comprise a first drop-stitch line set and a second drop-stitch layer may comprise a second drop-stitch line set. The first and second drop-stitch line sets may be substantially similar to one another. The first and second drop-stitch line sets are described in greater detail below.

[0040] The drop stitches 204 may extend through at least a portion of base cloth 212, along an entirety of the space 202, and through at least a portion of base cloth 222. Drop stitches 204 may comprise a dense array of stitches, and these stitches may be in a linear, zigzag, or random pattern with a stitch density within a range of 6-45 stitches per square inch. The space 202 between the base fabrics 212 and 222 may comprise the drop-stitching thread 204 and air. The space between base fabrics 212 and 222 may be adjusted based on a degree of inflation of the walls of an inflatable device. As one example, the drop-stitch 204 may be in the range of 5-7 centimeters when the inflatable device is at the desired degree of inflation, the desired degree of inflation determined based on one or more of a desired rigidity of the inflatable device shape and the shear modulus of the drop-stitch fabric. In other words, the spacing between base layer 212 and base layer 222 may be in the range of 5-7 centimeters when the inflatable device is at the desired degree of inflation. In this way, an inflatable device constructed from a drop-stitch fabric may be flexible and compressible when in a deflated state, providing improved portability. Further, the inflatable device may form a rigid shape when in an inflated state to provide a reliable sturdiness, tensile strength, and the ability to store both fluids and solid objects within walls of the inflatable device.

[0041] Inner layers 214 and 224 may be colligated in face-sharing contact to respective base cloths 212 and 222 via the use of adhesives, heat fusion, and/or a combination thereof. Similarly, inner layers 214 and 224 may be colligated in face-sharing contact to respective outer layers 216 and 226 via adhesives, heat fusion, and/or a combination thereof. In one example, the inner layer 214 may be colligated to base cloth 212 via heat fusion. At the same time, the inner layer 214 may be colligated to the outer layer 216 via adhesives. Inner layers 214 and 224 may be constructed from a reinforced polyvinyl chloride (PVC) material, or alternatively may be constructed from one of polyurethane (e.g., a thermoplastic polyurethane TPU) or Hypalon. By colligating an inner layer 214 or 224 to a respective base stitching layer 212 or 222 of the drop-stitch fabric, durability of the stitching may be improved.

[0042] Turning now to FIG. 2B, it shows a partially exploded view of the space 202 of the drop-stitch fabric 200. Specifically, the space 202 is separated into two portions, a first portion 207 and a second portion 209 via an interior layer 208. Herein, the interior layer 208 is referred to as a thermally insulating layer 208. In one example, the space 202 is configured to house air when the inflatable device is at least partially inflated. As such, the space 202 may herein be interchangeably referred to as air chamber 202. As shown, the first portion 207 and the second portion 209 are similarly sized and shaped with the thermally insulating material 208 located therebetween. In one example, the first portion 207 is in face-sharing contact with the base cloth 212 and the second portion 209 is in face-sharing contact with the base cloth 222.

[0043] Herein, the first portion 207 is a first drop-stitch layer 207 and the second portion 209 is a second drop-stitch layer 209. The first drop-stitch layer207 and the second drop- stitch layer 209 each comprise respective first drop-stitch line sets and second drop-stitch line sets which physically couple the drop-stitch layers to at least the thermally insulating material 208. Both the first drop-stitch layer 207 and the second drop-stitch layer 209 are planar- shaped.

[0044] As shown, the thermally insulating material 208 is shown as a single sheet located between the first 207 and second 209 drop-stitch layers. Drop-stitches (e.g., drop- stitches 204 of FIG. 2A) of the first 207 and second 209 layers may pass through the thermally insulating material 208. In alternative examples, the first drop-stitch layer 207 comprises a plurality of drop-stitches separate from and different than drop-stitches of the second drop-stitch layer 209. For example, drop-stitches of the first drop-stitch layer 207 may pass through the thermally insulating material 208 and the base cloth 212. Likewise, drop-stitches of the second drop-stitch layer 209 may pass through the thermally insulating material 208 and the base cloth 222. As such, drop-stitches of the first drop-stitch layer 207 do not extend into the second drop-stitch layer 209 or vice-versa.

[0045] The thermally insulating material 208 may comprise a non-conductive material impervious to airflow. The thermally insulating material 208 may be aluminized and reflective. Additionally or alternatively, the thermally insulating material 208 is an aerogel. In other embodiments, additionally or alternatively, the thermal break 208 is a foam. In one example, the thermally insulating material 208 is metallic. It will be appreciated that the thermally insulating material 208 is flexible and/or malleable when the inflatable device is deflated. When the inflatable device is inflated, pressure from gas contained in the first 207 and second 209 drop-stitch layers may force the thermally insulating material into a linear sheet with substantially rigid properties allowing the inflatable device to maintain an inflated shape.

[0046] In one example, the first 207 and second 209 drop-stitch layer face different environments. For example, if the first drop-stitch layer 207 faces an ambient environment, then the second drop-stitch layer 209 may face an interior space of the inflatable device and/or a user. As such, despite the various layers located between the space 202 and the outer shell 226 of FIG. 2A, the first 207 and second 209 drop-stitch layers experience different temperature fluctuations. In some examples, it may be desired for the inflatable device to maintain a desired temperature. In one example, if the inflatable device is an inflatable cooler, contents stored in the cooler are desired to be kept cool relative to an ambient temperature. As another example, if the inflatable device is a sleeping pad, a user sleeping thereon may desire to be kept at a temperature greater than a temperature of the ground with which the sleeping pad rests. The thermally insulating layer 208 substantially prevents and/or at least mitigates thermal communication between the first 207 and second 209 drop-stitch layers during an expanded condition of the inflatable device.

[0047] It will be appreciated that the inflatable device may comprise more than two drop-stitch layers. For example, the inflatable device may comprise three drop-stitch layers and two thermally insulating layers, wherein an insulating layer is located between each of the drop-stitch layers. In this way, an insulating device may comprise n drop-stitch layers and n-1 insulating layers. In one example, an inflatable device comprises eight drop-stitch layers and seven insulating layers. As will be described in greater detail below, the inflatable device may comprise only one valve to fill each the drop-stitch layers.

[0048] Thus, an inflatable device comprising a drop-stitch having a thermally insulating material separating the drop-stitch into first and second air cells, and where the thermally insulating material is configured to selectively or at least partially seal the first air cell from the second air cell based on an actuation of a valve of the inflatable device. The valve is directly coupled to the first air cell of the drop-stitch, and where the valve is configured to admit air directly into the first air cell. The thermally insulating material comprises flaps located at extreme ends of the thermally insulating material, and where the flaps elongate the thermally insulating material to a length greater than a length of the drop-stitch.

[0049] The flaps are rigid when the inflatable device is fully inflated, and where the flaps prevent air mixing between first and second air cells of the drop-stitch, and where the first air cell is on a first side of the thermally insulating material and where the second air cell is on a second side of the thermally insulating material opposite the first side. The flaps are bendy when the inflatable device is being inflated or deflated, and where the flaps allow air mixing between the first and second air cells.

[0050] The drop-stitch comprises two drop-stitches, a first drop-stitch located in the first air cell and a second drop-stitch located in the second air cell. The valve comprises a cap, and where the cap is moved away from the valve when the valve is being actuated. There are no other inlets and no other outlets other than the valve. There device is one or more of an inflatable cooler, an inflatable sleeping pad, an inflatable floatation device, and an inflatable pillow.

[0051] Turning now to FIGS. 3A and 3B, they show embodiments 300 and 350, respectively, of an inflatable device having the drop-stitch fabric 200 of FIGS. 2A and 2B. Thus, components previously presented may be similarly numbered in subsequent figures. Embodiment 300 illustrates a condition of the inflatable device where a valve 302 is not being actuated. Embodiment 350 illustrates a condition of the inflatable device where the valve 302 is being actuated. When the valve 302 is actuated, air may enter and/or exit the inflatable device. As such, when the valve 302 is not being actuated, air is contained within an outer shell 308 of the inflatable device. It will be appreciated that the outer shell 308 is in direct contact with an ambient atmosphere.

[0052] The outer shell 308 may provide the inflatable device with improved durability against abrasion, extreme conditions, or hazardous materials. As one non-limiting example, outer shell 308 may be a PVC material. However, in other examples, outer shell 308 may be formed from one of TPU, polyurethane, or Hypalon material. Outer shell 308 may further include may be a polyester material woven into a grid structure, and may provide the inflatable device with dimensional stability, tensile strength, and tear strength. Each face of outer shell may be colligated to drop-stitch fabric 200. The outer shell 308 is further configured to hold pressure. The pressure may be a result of admitting gas (e.g., air) into the inflatable device.

[0053] Spaces 311 located between the outer shell 308 and long edges of first 207 and second 209 portions indicate a location of the base fabrics 212, 222 and inner layers 214,224, respectively. However, spaces 312 located between the outer shell 308 and short edges of the first 207 and second 209 portions indicate a space where air may be present. Said another way, a portion of space 202 comprises a space (e.g., space 312) free of drop-stitch fabrics (e.g., drop-stitch fabrics of the first 207 and second 209 drop-stitch layers) that may still hold air.

[0054] The thermally insulating material 208 is shown as a double-walled material with a gap 314 located therein. The gap 314 is air-filled, in one example. Additionally or alternatively, the gap 314 is filled with foam or other thermally insulating material. In other examples, the gap 314 may be omitted and the thermally insulating material 208 may be a single-walled material. At any rate, a thickness of the thermally insulating material 208 may be between 0.1 to 0.3 millimeters. It will be appreciated that other thicknesses may be used without departing from the scope of the present disclosure.

[0055] The thermally insulating material 208 comprises a length greater than a length of either the first drop-stitch layer 207 or the second drop-stitch layer 209. Specifically, a first drop-stitch line set of the first drop-stitch layer 207 comprises a length substantially equal to a length of a second drop-stitch line set of the second drop-stitch layer 209. As such, the thermally insulating material is elongated relative to the first and second drop-stitch line sets of the first 207 and second 209 drop-stitch layers. In this way, flaps 304 are created on extreme ends of the thermally insulating material 208. In one example, each flap 304 is exactly 0.25 millimeters.

[0056] In some examples, additionally or alternatively, the thermally insulating material 208 is free at least one end. That is, the thermally insulating material 208 may be coupled to the outer shell 308 at one end. In one example, the thermally insulating material 208 is sealingly coupled to the outer shell 308 at one end. As a second end, the thermally insulating material 208 is not coupled to the outer shell 308. In this way, at least one end of the thermally insulating material 208 is freely arranged interior to the outer shell 308. [0057] The flaps 304 extend into space 312. The flaps 304 are configured to adjust a function of the space 312 such that in one condition, the space 312 acts as a channel permitting airflow between the first 207 and second 209 drop-stitch layers. In a second condition, the space 312 is prevented from fluidly coupling the first 207 and second 209 drop-stitch layer sand air does not flow between the first 207 and second 209 drop-stitch layers.

[0058] The valve 302 is in face-sharing contact with an ambient atmosphere and extends through the outer shell 308 and into the first drop-stitch layer 207. The valve 302 is hermetically sealed with the outer shell 308. The valve 302 may be sealingly coupled to the outer shell 308 via adhesives, stitches, and/or other coupling elements. Interior portions of the valve 302 may fluidly couple the first 207 and second 209 drop-stitch layers to an ambient atmosphere when a cap 303 of the valve 302 is opened (as shown in FIG. 3B). Specifically, the valve 302 directly couples the first drop-stitch layer 207 to the ambient atmosphere, whereas the second portion 209 is fluidly coupled to the ambient atmosphere via the space 312, first drop-stitch layer 207, and valve 302. In one example, the inflatable device comprises only one valve independent of a number of drop-stitch layers. Thus, there are no other inlets and no other outlets other than a single valve in a closed chamber formed by an outer shell enclosing the first and second air cells.

[0059] A thickness of the first drop-stitch layer 207 is based on a length of the valve 302. For example, if the valve 302 is 0.75 millimeters in length, then the thickness of the first drop-stitch layer 207 may be 1.25 millimeters. It will be appreciated that thicknesses of the first drop-stitch layer 207 and the second drop-stitch layer 209 may be substantially similar. As such, volumes of the first drop-stitch layer 207 and the second drop-stitch layer 209 may also be substantially similar. In this way, a pressure of the first drop-stitch layer 207 is substantially equal to a pressure of the second drop-stitch layer 209 when the inflatable device is in an inflated state.

[0060] Thus, a drop-stitch comprises a chamber having a first drop-stitch layer with a first length and a second drop-stitch layer with a second length, where the first length is equal to the second length, a thermally insulating material located between the first and second drop-stitch layers having a third length, where the third length is greater than the first and second lengths, and a single valve coupled to the first drop-stitch layer. The third length is greater than the first and second lengths by 0.1 millimeters. The thermally insulating material includes at least one flap and/or free end, which is adjusted in response to actuation of the valve. Herein, the thermally insulating material is described as having two flaps, with each flap having a free end configured to slidingly engage with interior surfaces of the outer shell 308 to form at least a partial seal.

[0061] The flaps are adjusted to a rigid position exactly between the first and second drop-stitch layers when the valve is not actuated and air is not admitted to or escaping the drop-stitch, and where the rigid position prevents air flow and thermal communication between the first and second drop-stitch layers. The flaps are adjusted to a flexible position where the flaps are biased toward the first drop-stitch layer or the second drop-stitch layer when the valve is actuated and air is flowing to or flowing away from the first and/or second drop-stitch layers, and where the flexible position allows air flow and thermal communication between the first and second drop-stitch layers. The thermally insulating material is a single layer composed of a metallic material. The thermally insulating material is double-walled with an airgap located therebetween. A height of the first drop-stitch layer is 1.25 millimeters and a height of the valve is 0.75 millimeters.

[0062] Turning now to FIG. 3A, embodiment 300, herein referred to as inflatable device 300, is shown in a fully inflated state. Circles 306 represent air and may herein be referred to as air 306. Space 202 is herein referred to as air chamber 202. Furthermore, first drop-stitch layer 207 and second drop-stitch layer 209 are herein referred to as first air cell 207 and second air cell 209. Drop-stitches of the first air cell 207 and the second air cell 209 are illustrated via vertical lines and may be used similarly to drop-stitches 204 of FIG. 2A. However, it will be appreciated that the drop-stitches of both or either of the air cells may deviate from linear without departing from the scope of the present disclosure. Herein, the drop-stitches of the first air cell 207 are referred to as a first drop-stitch line set and the drop- stitches of the second air cell 209 are referred to as a second drop-stitch line set.

[0063] The valve 302 is not being actuated and is sealed from an ambient atmosphere as shown by the cap 303 being flush with a body of the valve 302 in FIG. 3A. In this way, air may not flow through the valve 302. As such, the inflatable device 300 maintains a current inflation amount, which is fully inflated in the example of FIG. 3 A.

[0064] In the inflated state, the first air cell 207 is fluidly and thermally separated from the second air cell 209. As shown, the flaps 304 are rigid and extend in a direction parallel to the length of the thermally insulating material 208. This may be due to equal opposite forces acting upon the thermal insulating material 208 from the first 207 and second 209 air cells. In this way, the flaps 304 are slightly spaced away from the outer shell 308 such that little to no air flows between the first air cell 207 and the second air cell 209. Said another way, the flaps 304 at least partially seal the first air cell 207 from the second air cell 209. Additionally or alternatively, the flaps 304 may be pressed against interior surfaces of the outer shell 308 when in the fully extended, rigid state. As illustrated, air 306 collides with the flaps 304 when the inflatable device 300 is in the inflated state due to natural air currents created in the first 207 and second 209 air cells. However, the flaps 304 remain rigid and do not give way such that the air 306 is maintained in its respective air cell.

[0065] As an example, if the inflatable device 300 is an inflatable cooler, then the first air cell 207 may face an interior of the cooler where contents are stored (e.g., food, drinks, etc.). As such, the second air cell 209 may face an ambient atmosphere or a ground on which the cooler is placed. A temperature change of the second air cell 209 is different than that of the first air cell 207. In one example, the second air cell 209 is warmer than the first air cell 207. The thermally insulating material 208 prevents heat transfer between the first 207 and second 209 air cells, while the flaps 304 specifically prevent air flow between the first 207 and second 209 cells. In this way, the warmer air from the second air cell 209 does not communicate and/or mix with cooler air in the first air cell 207.

[0066] As another example, if the inflatable device 300 is an inflatable sleeping pad, then the first air cell 207 may face a user lying thereon. As such, the second air cell 209 may face a ground on which the sleeping pad is situated. A temperature change of the second air cell 209 is different than that of the first air cell 207. Specifically, the user may be warmer than the ground such that a temperature of the first air cell 207 may increase and a temperature of the second air cell 209 may decrease relative to starting temperatures of the air cells. Due to equal pressures being exerted from the first 207 and second 209 air cells in opposite direction onto the thermally insulating material 208, cool air from the second air cell 209 does not mix or communicate with warm air in the first air cell 207. In this way, a user may experience warmer temperatures while using an inflatable device having the thermally insulating material 208 with flaps 304 compared to a sleeping pad having a thermally insulating material excluding the flaps (e.g., a thermally insulating material that is not elongated).

[0067] Turning now to FIG. 3B, it shows embodiment 305, here referred to as an inflatable device 350, in a partially inflated state. Specifically, the inflatable device 350 is shown being inflated by a user or auxiliary device actuating the valve 302. As illustrated, air is admitted through the valve 302 and into the first air cell 207. The lid 303 is opened and angled up and away from a body of the valve 302 such that the user may access the valve 302. [0068] As air enters the first air cell 207, a pressure of the first air cell 207 is greater than a pressure of the second air cell 209. The first 207 and second 209 air cells are unequal sizes during inflation due to the first air cell 207 initially receiving a greater amount of air 306, thereby allowing the first air cell 207 to expand to a greater size than the second air cell 209. The flaps 304 succumb to the pressure of the first air cell 207 and depress toward the second air cell 209. In this way, a space between the flaps 304 and interior surfaces of the outer shell 308 increases and air 306 may flow through the space created and into the second air cell 209. In this way, the first 207 and second 209 air cells are fluidly coupled and may be filled via a single valve (e.g., valve 302). Air may continue to flow into the second air cell 209 from the first air cell 207 until a pressure of the first air cell 207 is substantially equal to a pressure of the second air cell 209. The first 207 and second 209 air cells are substantially equal once the air cells comprise a similar amount of air.

[0069] Although the embodiment of FIG. 3B shows air flowing between the first air cell 207 and the second air cell 209 while the inflatable device is being inflated, a substantially opposite air flow may occur when the inflatable device is being deflated. As such, air may flow between the first and second air cells, through the valve 302, and into an ambient atmosphere.

[0070] Thus, a method for an inflatable device comprises flowing air between first and second air cells via actuating a valve of the inflatable device and bending flaps of a thermally insulating material located between the first and second air cells and preventing air flow between first and second air cells when the valve is not actuated by maintaining a rigidity of the flaps of the thermally insulating material. The first air cell comprises a first drop-stitch and where the second air cell comprises a second drop-stitch, and where the thermally insulating material traverses an entire length of the first and second drop-stitches, and where the flaps elongate a length of the thermally insulating material to a length greater than the entire length of the first and second drop-stitches.

[0071] Preventing air flow further includes maintaining a pressure of each of the first and second air cells, and where flowing air between the first and second air cells includes adjusting a pressure of the first and second air cells.

[0072] In this way, a chamber of an inflatable device is divided into a first air cell and a second air cell. A thermally insulating material may selectively separate the first air cell and the second air cell when the inflatable device is fully inflated and a pressure imparted onto the thermally insulating material by the first and second air cells is substantially equal. The thermally insulating material may also selectively coupled the first air cell and the second air cell when the inflatable device is being inflated or deflated. The technical effect selectively separating and coupling the first and second air cells via the thermally insulating material is include only a single valve for inflating or deflating the inflatable device. In this way, a manufacturing cost of the inflatable device is decreased compared to an inflatable device having fully separated air cells with individual valves.

[0073] Turning now to FIGS. 4 A and 4B, they show example configurations 400 and 450, representing the inflatable devices without drop-stitch (and without any interior foam) where the valve 302 is not being actuated (400) and being actuated (450). Components previously presented may be similarly numbered here. FIGS. 4 A and 4B show examples of air flow through the first and second cells without drop-stitch. Air cells without drop-stitch may further present an advantage of allowing the surface of the inflatable cooler to easily conform to the shape of the items contained within the inflatable cooler or a predetermined shape but with less weight and cost yet still with substantial insulation capabilities. It will be appreciated that a further example embodiment could be presented to include 3 air cells or more depending on the need for insulation, and different panels may have different numbers of layers, as just one example.

[0074] FIGS. 4A-4B show other embodiments (where drop-stitch is not present) comprising an elongated interior layer which may have at least one free end at one end, the free end only partially sealing, but not permanently sealing the cells from one another via, for example, engagement with an inner surface of the outer shell.

[0075] Turning now to FIGS. 5 A and 5B which show an inflatable cooler in the unfolded configuration 500 and the folded configuration 550 comprising an inflation valve 120 and six connected panels 501A-F sharing an air chamber. Each panel may comprise both a first air cell or first layer 207 and a second air cell or second layer 209. The chamber fluidically connects all the panels by an opening 502.

[0076] The first and second air cells may be fluidically connected by flaps 304 opening to allow air 306 to move to and from the first and second air cells. The first and second air cells 207 and 209, respectively, may also be fluidically connected by a connecting air valve 601. The panels are further fluidically connected via openings 502. Each crease 505 assists adjacent panels 501 to pivot so that the connected panels form a folded configuration 550. The creases may be formed by stiches, an adhesive, or by a heat sealant or by any other means necessary aid the panels in forming the folded configuration 550. The formation of the creases may block transport of air where the creases occur. An opening 502 fluidically connects all the panels where the creases may block passage of air from one panel to the next. [0077] The connected panels further share a zipper 503 along the perimeter. The zipper 503 along the perimeter of the connected panels may connect the edges of the panels so that the panels become a folded configuration in the form of a rectangle in this example (although other shapes may be used, such as a shopping bag shape, or others). The zipper 503 may surround the perimeter of the connected panels in order for the folded configuration 550 to connect completely by a continuous zipper. Having the folded configuration in this way may improve a thermal seal with one continuous zipper 503 and reduce manufacturing costs and may increase ease of use. An example starting location for the zipper is at the zipper starter 504.

[0078] Turning now to FIGS. 6A and 6B, which show example embodiments of a cross- sectional views of the panels 501 containing no drop-stitches in either one of the air cells or first or second layers 207 or 209. The air cells are separated by an interior layer 208; the layer may be a thermally insulating material or the same material as the other portions of the panel, and may have flaps 304, with at least one flap at each end, the flaps each having a free end that slidingly engages with an outside layer enclosing the first and second airs cells. The flaps may be more rigid when the inflatable cooler is fully inflated, where the flaps reduce air mixing between first and second air cells of the panels 501, and where the first air cell 207 is on a first side of the thermally insulating material and where the second air cell 209 is on a second side of the thermally insulating material opposite the first side. The flaps are bendable when the inflatable device is being inflated or deflated, and where the flaps allow air mixing between the first and second air cells to enable the device to be deflated.

[0079] The layer 208 may also have another connecting air valve 601 shown in embodiment 650. The air valves 601 are rigid when the inflatable cooler is fully inflated, and where the air valves 601 reduce air mixing between first and second air cells of the panels 501, and where the first air cell 207 is on a first side of the thermally insulating material and where the second air cell 209 is on a second side of the thermally insulating material opposite the first side. The air valves 601 may be more bendable when the inflatable cooler is being inflated or deflated, and where the flaps allow air mixing between the first and second air cells.

[0080] Each of the air cells 207 and 209 in the panels 501 may be fluidically connected by one or more air valves 501. The air cells may also further be fluidically connected by openings 502 between the panels. Each of the air cells may be held in place within a panel by two or three connecting layers 602 permeable to air 306. [0081] In still another example, the panels described above may include alternative layering structures. Thus, the layers may include two discrete layers: an upper layer 706 and a lower layer 701. Each layer 706 and 701 may be comprised of an open-cell, foam material, or inflatable layers including a foamless, air containing layer. Each of these layers can be inflated to a different inflation level based on a user's preference, or they may share communication to be inflated to a common pressure.

[0082] The layers may share a common valve or each have their own valve (upper layer valve 705 and a lower layer valve 702).

[0083] In one example, the upper layer is attached to the lower layer by using several small welded tabs arranged along the outer edges of the two layers as shown, or another fastening structure. The welded tabs may be ultrasonically welded tabs.

[0084] In FIG. 7, upper and lower panel layers 706 and 701 share a separation layer 703 made of an air impermeable material. In some examples, the separation layer 703 is air tight so that the different air pressures of the upper and lower layers 706 and 701 may be maintained. In other examples, there is some communication between the layers so that they share a more similar pressure. The material chosen for the separation layer 703 includes, but is not limited to, laminated or coated fabrics, polyesters, polyurethane film or another film material, Mylar or any other appropriate material. In addition, the separation layer 703 may be made of an insulating material and/or include a heat reflective material such as a thin metalized layer on at least one side of the separation layer 703. In addition, either or both of the top and bottom layers 706 and 701 of the dual-layer panel 700 may include a metalized layer for heat reflection.

[0085] Foam material 705 may or may not be present in either the top layer 706 or the bottom layer 701 or both the top and bottom layers 706, 701, as is shown in FIG. 7. It is also contemplated there is no foam in either the top or bottom layers 706, 701.

[0086] The top layer 706, the bottom layer 701 and the separation layer 703 can all be connected to one another in the end region 740. One connection method is a weld, wherein the top layer 706, the separation layer 703 and the bottom layer 701 are all welded together.

[0087] Another example wherein either one of the upper or lower layers or both of the layers does not include foam and is provided in the shape of baffles or alternatively ribs to maintain structural integrity when inflated, such that the panel 700 stays flat or planar. The absence of the foam may reduce weight, while still providing additional cushioning and stability, while maintaining the user's ability to inflate the lower layer 701, 701 a or 701 b to the same or a different pressure than the upper layer 706. The upper and lower layers, 706 and 701 may be permanently or releasably connected as described herein.

[0088] In, FIG. 8, panel 800 (which may be a panel of the cooler examples described herein) includes a top layer 808 and a bottom layer 807 separated by a separation layer 803. The separation layer 803 may or may not include insulation. The panel 800 includes an upper layer valve 815 and a lower layer valve 802. Or may include only one valve where there is air communication, at least partially, between the layers.

[0089] Multiple film layers may be included and welded together to create a baffle configuration. The multiple film layers of the top layer 808 include an upper outer film layer 811, which forms the outermost upper surface of the panel. An upper baffle film layer 810 with a lattice structure is located below the upper outer film layer 811. An upper inner film layer 812 is located below the upper baffle film layer 810 and is also in contact with the separation layer 803. The multiple film layers of the bottom layer 807 include a lower outer film layer 814, which forms the outermost lower surface of the panel. A lower baffle film layer 809 with a lattice structure is located above the lower outer film layer 814.

[0090] A plurality of connection points 806 are created, possibly by welding, wherein the upper baffle film layer 810, upper inner film layer 812, and lower baffle film layer 809 and separation later 803 are welded together. The combination of the lattice structure of the upper baffle film layer 810 and the lattice structure of the lower baffle film layer 809 and the plurality of connection points 806 form the baffle design as seen in FIG. 8.

[0091] The following claims particularly point out certain combinations and subcombinations regarded as novel and non-obvious. These claims may refer to "an" element or "a first" element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.

Claims

CLAIMS:

1. An inflatable cooler comprising:

first and second air cells having a material layer separating said first and second air cells, the layer configured to selectively or partially seal the first air cell from the second air cell.

2. The inflatable cooler of claim 1, wherein the first and second air cells comprise a drop stitch.

3. The inflatable cooler of claim 1, wherein the layer includes thermally insulating material, and wherein a valve included in only one of the first and second air cells, and where the valve is configured to admit air directly into the one cell.

4. The inflatable cooler of claim 3, wherein the valve is coupled to the first cell, and wherein the thermally insulating material comprises flaps located at extreme ends of the thermally insulating material, and where the flaps elongate the thermally insulating material to a length greater than a length of the drop-stitch, and wherein the flaps each have a free end to form the seal.

5. The inflatable cooler of claim 4, wherein the flaps reduce air mixing between the first and second air cells of the drop-stitch, and where the first air cell is on a first side of the thermally insulating material and where the second air cell is on a second side of the thermally insulating material opposite the first side.

6. The inflatable cooler of claim 5, wherein the flaps include fabric material, and where the flaps allow air mixing between the first and second air cells when inflating and deflating the device.

7. The inflatable cooler of claim 1, wherein the cooler is formed from only a single combined set of panels that connect together, the panels having only a single valve and each panel fluidically communicating with the other panels.

8. The inflatable cooler of claim 1, wherein there are no other inlets and no other outlets other than a single valve in a closed chamber formed by an outer layer enclosing the first and second cells.

9. The inflatable cooler of claim 7, wherein there is no foam or drop-stitching in the panels.

10. An inflatable cooler, comprising:

a plurality of fluidically coupled panels, the panels flexibly coupled to one another and configured to be removably coupled together to form the cooler, each panel having a chamber having a first air cell with a first length and a second air cell with a second length, where the first length is equal to the second length; and

a single valve coupled to the first air cell and positioned in a cooler panel.

11. The inflatable device of claim 10, wherein at the least the first or second air cell comprises a drop stitch.

12. The inflatable device of claim 10, wherein the panels do not have insulation and do not have drop-stitch.

13. The inflatable device of claim 10, wherein an interior layer includes flaps, with at least one flap at each end, the flaps each having a free end that slidingly engages with an outside layer enclosing the first and second cells, and wherein the flaps reduce air flow and thermal communication between the first and second air cells.

14. The inflatable device of claim 13, wherein the cells are planar-shaped and are in face- sharing contact with the interior layer.

15. The inflatable device of claim 13, wherein the interior layer is a single layer composed of a metallic material.

16. The inflatable device of claim 13, wherein the panels are removeably coupled via a zipper.

17. The inflatable device of claim 13, further comprising a height of the first air cell being at least 1.25 millimeters and a height of the valve being at least 0.75 millimeters.

18. An inflatable cooler comprising a valve and six connected panels sharing a common air chamber; the connected panels removably coupled to one another via a zipper along a perimeter of a combined element formed by the six connected panels.

19. The inflatable cooler of claim 18, wherein at least one panel comprises a double layer of air cells.

20. The inflatable cooler of claim 19, wherein the air cells are separated by an interior layer; wherein the layer comprises flaps, with at least one flap at each end, the flaps each having a free end that slidingly engages with an outside layer enclosing the first and second cells.