Corrugated Cardboard Cooler With Collapsible Folded Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coolers formed from a folded sheet of material with a water-resistant coating lack alternative designs that are collapsible, recyclable, and efficient for use as ice containers.
Innovation Solution
A cooler made from a single sheet of corrugated cardboard that can be folded into an assembled configuration for use and collapsed for storage, shipping, disposal, or recycling, featuring fold lines, perforations, and a locking mechanism for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cooler is made from a single sheet of corrugated cardboard with fold lines and locking mechanisms, then it can be collapsed for storage and recycling, but the structural strength and reliability may be compromised
Solution Approach 1:
The cooler is divided into multiple panels (front, back, side panels) connected by fold lines, allowing the structure to be segmented for collapsing while maintaining strength when assembled. The locking mechanisms further segment the closure function from the main body.
Solution Approach 2:
The cooler uses corrugated cardboard, a composite material consisting of fluted paper sandwiched between flat liners, providing high strength-to-weight ratio. This composite structure maintains reliability while enabling collapsibility.
2Ease of operation
If finger openings are provided in the top panels for handholding, then ease of operation is improved, but structural integrity of the top panels may be weakened
Solution Approach 1:
The top panels have different local qualities: areas with finger openings are optimized for grip, while other areas maintain full structural integrity. The openings are strategically positioned to provide handholds without compromising overall panel strength.
3Strength
If flaps are added to cover the handhold opening, then insulation and structural integrity are improved, but device complexity increases
Solution Approach 1:
The flaps are merged with the existing panel structure through fold lines, combining the closure function with the structural panels. This integration adds minimal complexity while providing effective coverage of the handhold openings.
Data Source
AI summary
A box is made by folding a sheet of material. Preferably, the box is formed by applying adhesive and folding using a machine, and a waterproof or water-resistant coating is applied to the sheet of material so that the box is configured for use as a cooler. The box includes: a storage portion, including a bottom panel, first and second end panels, and first and second side panels; four corner panels; and first and second top panels. The top panels include openings that register when the box is assembled and in a closed configuration to define an opening to be used as a handhold for gripping the box. Reinforcing panels of one of the top panels includes flaps located on an interior of the box that cover the handhold opening. The box further preferably includes a locking tab and locking panel for latching closed the top panels of the box.