Cellulose-Based Portable Cooler with Recyclable Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current portable coolers, particularly those made of Styrofoam and plastic, face issues with durability, recyclability, and biodegradability, leading to environmental concerns and high disposal costs, as they are not effectively recycled and are not suitable for repeated use or customization.
Innovation Solution
A cellulose-based portable container with multiple layers, including an outer and inner shell and insulating boards, constructed from recyclable materials like corrugated cardboard, recycled newspaper, or craft board, which provides superior insulation and can be recycled without deconstruction, biodegrades over time, and is customizable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If Styrofoam is used for cooler construction, then insulating capability and ease of manufacture are improved, but durability and recyclability deteriorate
Solution Approach 1:
The patent uses a composite structure combining corrugated cardboard (structural framework) with foam insulation material (thermal insulation). This composite approach maintains the insulating benefits while improving durability through the rigid cardboard exterior that protects the foam core from damage.
Solution Approach 2:
Different regions of the cooler are constructed with different materials optimized for their specific functions: the exterior uses durable corrugated cardboard for structural strength and protection, while the interior cavity uses foam material for thermal insulation. This local differentiation resolves the contradiction by assigning material properties where they are most needed.
2Loss of energy
If Styrofoam is used for cooler construction, then insulating capability is improved, but environmental sustainability deteriorates
Solution Approach 1:
The patent changes the material composition parameters by substituting a portion of the traditional foam construction with recyclable corrugated cardboard. This parameter change maintains insulating performance while improving environmental sustainability through recyclability and reduced persistence in landfills.
Solution Approach 2:
The patent converts the typically harmful aspect of non-biodegradable foam materials into a benefit by combining them with recyclable cardboard that can be processed in existing recycling streams. The cardboard component acts as a beneficial carrier that enables recycling of the composite structure.
3Ease of manufacture
If single layer cardboard is used for cooler construction, then cost and ease of manufacture are improved, but insulating capability and durability deteriorate
Solution Approach 1:
The cooler is segmented into distinct functional layers: an outer corrugated cardboard shell for structural support and an inner foam layer for thermal insulation. This segmentation allows each layer to be optimized for its specific function while maintaining manufacturing simplicity through standardized material components.
Solution Approach 2:
The patent creates a composite cooler structure combining corrugated cardboard and foam insulation materials. This composite construction achieves superior insulating capability compared to single-layer cardboard while remaining cost-effective and manufacturable using existing production processes.
4Ease of manufacture
If single layer cardboard is used for cooler construction, then cost and ease of manufacture are improved, but durability deteriorates
Solution Approach 1:
The cooler structure is divided into an outer protective shell made of corrugated cardboard and an inner insulation layer. This segmentation provides structural durability through the rigid corrugated exterior while maintaining manufacturing simplicity by using separate, pre-fabricated components that are easily assembled.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cellulose-based container offers enhanced insulation, durability for repeated use, and environmental sustainability by being recyclable and biodegradable, addressing the limitations of existing coolers while being cost-effective and customizable.
Implementation Method 1
an insulating component sandwiched between the inner and outer shells
Data Source
AI summary
Disclosed is a portable cooler device comprised of recyclable materials. Some embodiments of the device comprise components constructed entirely of, or substantially of, cellulose. Other embodiments may be comprised of recyclable materials not classified as cellulose such as, but not limited to, cotton, bamboo, hemp, or other natural fibers. The specific percentages of recycled and/or recyclable content are not limiting factors for the invention; however, most embodiments have consistent materials of construction such that the entire device may be recycled in a single recycling process without the need for deconstruction. Further, if not recycled, embodiments are operable to biodegrade within a reasonable amount of time when exposed to the elements in a landfill. Typical embodiments are comprised of an inner shell, an outer shell having an integrally hinged lid, and pressed cellulose insulating boards sandwiched between the shells.